DC Drilling Motor Maintenance Manual - Joliet Electric Motors

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Joliet Equipment Corporation

Engineered Drilling Motors

Maintenance & Spare Parts Manual

Models: JEC75YZB, JEC75YZE, JEC75ZB, JEC75ZE, JEC75ZB-F, JEC75ZE-F

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General Product Information Parts List/Diagram 6-7Models 8Differences Between Models 9General Specifications 10-12General Operation Information 13 GeneralFeatures 13 ATEXCertificationSafetyConsiderations 13 SafeElectricalParameters–ShuntWound 14 SafeElectricalParameters–SeriesWound 14 Warnings 14-15 ClosedCoolingSystems 15 SpecialHandlingRequirements 15 Grounding 15-16 Lubrication 16 SpecialTools 16Inspections 17 MonthlyInspections 17-19 InspectionpriortoOperation 20 InspectionsforClosedCoolingSystems 20 Semi-AnnualInspections 20Motor Overhaul 21 TestingtheMotorbeforeDisassembly 21 DisassemblingtheMotor 21 RemovingtheHub 21-22 RemovingtheArmatureFromtheFrame 22-23 TestingafterOverhaul 23 TestingSeriesModels 23 TestingShuntModels 24Cleaning 25 SteamCleaning 25 VaporDegreasing 25

CleaningAnti-FrictionBearings/ShaftTapers/BearingFits 25

Contents

Con

tent

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Rev. 07152010

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Working with the Motor Parts The Brush and Brushholder ReplacingtheBrushes 26 RemovingtheBrushes 26 InstallingtheBrushes 26 ReplacingtheBrushholders 26 InstallingtheBrushholders 27 AdjustingtheBrushholderClearance 27 InspectingandTestingtheBrushholders 27 ReplacingtheBrushholderSleeves 27 ReassemblingBrushholders 28The Armature 28 InspectingandTestingtheArmature 28 ReplacingtheArmatureCreepageBand 28 AssemblingtheArmatureintotheFrame (ModelsYZE,YZK,ZE-F,ZK-F,ZE,ZK) 28-30 AssemblingtheArmatureintotheFrame (ModelsYZB,YZH,ZB-F,ZH-F,ZB,ZH) 30-31 RemovingtheArmatureLockingArrangement 31 LockingtheArmatureforShipment 31 TestingtheArmatureafterRepair 31 ArmatureVarnishTreatment 32 BalancingtheArmature 32Inspections 32 InspectingtheInsulation 32 InspectingtheCommutator 32 InspectingtheArmatureShaftBearingFits 32 InspectingtheCreepageBand 32Resurfacing the Commutator 33 Grinding 33 Turning 33 Undercutting 33 Raking 34 Polishing 34

The Motor Frame 35 Inspecting and Testing the Motor Frame 35 ReplacingtheMotorFrameFieldCoil 35 RemovingtheCoil 35 InstallingtheCoil 36

:Contents: P

art 2

Contents

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The Motor Frame (continued)Brazing the Coil Terminals 36 UsingtheMachineBrazingMethod 36 UsingtheGasTorchBrazingMethod 36 FloodDippingtheCoiledFrame 37Testing the Coiled Frame 37 TestingafterRepair(withoutArmature) 37 TestingafterRepair 37The Connection Boxes 38 ChangingthePositionoftheConnectionBox 38-39 InsulatingtheTerminalConnections 39 AssemblingtheConnectionBox 39-40 DifferencesforShuntMotors 40The Commutator 41 ResurfaceBasedonCondition 41 SafetyRequirements 41 PreparingtheCommutatorforResurfacing 41 PreparingforResurfacingforSeriesMotors 41 PreparingforResurfacingforShuntMotors 42 SandingtheCommutator 42 HandStoningtheCommutator 42-43 FixtureGrinding 43 InstallingtheGrinder 43 GrindingtheCommutator 43-44 AirCuringtheCommutator 45The Bearings 46 InspectingtheBearings 46 ReassemblingtheBearings 46 ReassemblingtheArmatureBearings 46 ReassemblingtheDrive-EndBearing46-47 ReassemblingtheCommutator-EndBearing(ShuntWoundMachines) 47 ReassemblingtheCommutator-EndBearing(SeriesWoundMachines) 47The Hubs 48 HubFitting 48 MountingtheHub 48-49The Bolts50 LubricatingtheBolts50

StandardBoltTorqueValues 51

Index 52-54

Contents

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JOLIETEquipmentCorporationcontinuouslyinvestsinglobalmanufacturingalliancestobringthebestinelectricmotorsandrelatedtechnologytoAmerica.

OneofNorthAmerica’sleadingsuppliersoflarge,heavy-dutyelectricmotors,JOLIETEquipmentCorporationhasbeenbuildingandrebuildingelectricmotorsformorethan75years–withbettervalueandunequaledqualityandsupport.JOLIETEquipmentCorporationmeanspower–insteelmills,papermills,petrochemicaloperationsandhigh-performance,

deep-drillingoffshoreequipment–settingheavy-dutyoperatingstandardsfromtheAmericastothePacificRimandcustomersitesaroundtheworld.

Formorethantwogenerations,JOLIETEquipmentCorporationhasbeensettingqualitystandardsandspecificationsforelectricmotors.CarefullychosenalliancesandqualitycontrolmeasuresinsurethatJOLIETEquipmentCorporationcustomerswillreceivetheabsolutebestinelectricmotorperformanceandvalue.

General Product Information

Joliet Equipment Corporation Bringing You the Best in Electric Motors

General P

roduct Information

Reconditioned DC Drilling MotorsJEC75ZB JEC75ZE JEC75YZF

(Top Drive) JEC75ZB-F JEC75ZE-F

Type: (Series/Shunt) Series Shunt Series/Shunt Series Shunt

HP: (Continuous) 1000 1000 1085/1130 1085 1130

HP: (Intermittent) 1250 1250 1320/1365 1320 1365Voltage: (VAC) 750 750 750 750 750Full Load Current: (Continuous) 1050 1050 1150/1185 1150 1185Full Load Current: (Intermittent) 1400/1435 1400 1435Full Load RPM: 965 1040 965/1040 965 1040Horizontal / Vertical: Horizontal Horizontal Vertical Horizontal HorizontalTorque: (@ Base RPM): (Continuous) 5200 5050 5900/5705 5900 5705Torque: (@ Base RPM): (Intermittent) 6800 6300 7530/6745 7530 6745Available Certification: ABS ABS ABS∙ATEX ABS ABSApprox. Weight: (lbs.) 6900 6900 7150 7150 7150

Add“1”aftermodelnumberforMarineDutyAdd“3”aftermodelnumberforLandDuty

New DC Drilling MotorsJEC75YZB JEC75YZE JEC75ZF

(Top Drive)Type: (Series/Shunt) Series Shunt Series/Shunt

HP: (Continuous) 1085 1130 1085/1130

HP: (Intermittent) 1320 1365 1320/1365Voltage: (VAC) 750 750 750Full Load Current: (Continuous) 1150 1185 1150/1185Full Load Current: (Intermittent) 1400 1435 1400/1435Full Load RPM: 965 1040 965/1040Horizontal / Vertical: Horizontal Horizontal VerticalTorque: (@ Base RPM): (Continuous) 5900 5705 5900/5705Torque: (@ Base RPM): (Intermittent) 7530 6745 7530/6745Available Certification: ABS∙ATEX ABS∙ATEX ABS∙ATEX

Approx. Weight: (lbs.) 7150 7150 7150

Add“1”aftermodelnumberforMarineDutyAdd“3”aftermodelnumberforLandDuty

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DESCRIPTION PART NUMBER1 Outer Seal 10-53 D00112 Drive-End Outer Bearing Cap 10-53-D00123 Drive-End Bearing Cap Bolts 10-53-D00134 Bearing Cap Lock Washers 10-53-D00145 Drive-End Outer Gasket 10-53-D00156 Drive-End Bearing 10-53-D00167 Hi-Torque Endbell 10-53-D00178 Bolts & Washers 10-53-D00189 Drive-End Bearing Spacer/Slinger 10-53-D001910 Drive-End Inner Bearing Cap 10-53-D002011 Inner Seal 10-53-D002112 Cable S2 10-53-L002213 Cable S1 10-53-L002314 Cable A2 10-53-L002415 Cable A1 10-53-L002516 Frame/Lead Grommet 10-53-L002617 Blower Seal Tite 10-53-L002718 Seal Tite 10-53-L002819 Seal Tite 10-53-L002920 Armature with Shaft 10-53-A003021 Exhaust Cover B 10-53-F003122 Exhaust Cover C 10-53-F003223 Exhaust Cover A 10-53-F003324 Exhaust Cover D 10-53-F003425 Inner-pole Bolt 10-53-F002526 Inner-pole Pole Piece 10-53-F003627 Inner-pole Coil 10-53-W003728 Inner-pole Shims 10-53-F003829 Inner-pole Shims 10-53-F003930 Commutator Covers - Upper 10-53-F004031 Field Coil Bolt 10-53-F004132 Field Coil Bolt Washer 10-53-F004233 Field Coil Open 10-53-W004334 Field Coil Crossed 10-53-W004435 Field Coil Spring Plate 10-53-F004536 Field Coil Pole Piece 10-53-F004637 Frame 10-53-F004738 Blower Mount Bolt 10-53-B004839 Blower Mount Washer 10-53-B004940 Blower Assembly 10-53-B005041 Commutator-End Bearing Cap Bolts 10-53-C0051

DESCRIPTION PART NUMBER42 Commutator-End Outer Bearing Cap 10-53-C005243 Commutator-End Bolts & Washers 10-53-C005344 Gaskets 10-53-C005445 Commutator-End Endbell 10-53-C005546 Commutator-End Bearing Lock Nut

Set Screw10-53-C0056

47 Commutator-End Bearing Lock Nut 10-53-C005748 Commutator-End Bearing / Outer Ring 10-53-C005849 Commutator-End Bearing 10-53-C005950 Commutator-End Inner Bearing Cap 10-53-C006051 Brush Holder Assembly 10-53-C006152 Carbon Brush 10-53-C006253 Washer 10-53-F006354 Bolt 10-53-F006455 Bottom Bolt-on Cover 10-53-F006556 Bottom Spring Cover 10-53-F006657 Copper Bus Connection 10-53-T006758 Terminal Box Covers 10-53-T006859 Bolt 10-53-T006960 Washer 10-53-T007061 Bolt 10-53-T007162 Washer 10-53-T007263 Washer 10-53-T007364 Glastic Stand Off 10-53-T007465 Bolt 10-53-T007566 Connection Plate 10-53-T007667 Gland 10-53-T007768 Terminal Box 10-53-T007869 Crouse-Hinds Lockout Switch 10-53-T007970 Pressure Switch (XP) 10-53-T008071 Space Heater (120/240 VAC) 10-53-T008172 Terminal Board w/Indicator 10-53-T008273 Oilfield Hub 10-53-S008374 Hi-Torque Endbell 10-53-D008475 Exhaust Cover Gasket 10-53-F008576 Nomex Gasket 10-53-F008677 Nomex Gasket 10-53-F008778 Blower Gasket 10-53-B008879 Blower Filter 10-53-B0089

Par

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Dia

gram

Parts List/Diagram

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Parts List/D

iagram

57 9 10

12 13 14 15 16 17 18 19

20

11

21

22

2324

25 26 27 76 28 29 30 31 32 33 34 35 36 77 78

37

38 39 40

79

4

41

42

43

45

46

51

5253

5455

5657

58

4596060 6163 62646539666768

8

44

4748

4950

70

69 72

71

1

2

3

4 5 6

73

74

75

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Model Series Wound (H) Shunt Wound (K)

C75ZB(E)Reconditioned 1000HP DC Drilling

• Continuous rating for mud pump and rotary table applications of 1000 HP• Intermittent rating for drawworks applications of 1250 HP• Continuous rating is at 750 VDC, 1050 Amperes, 965 RPM

• Continuous rating for mud pump and rotary table applications of 1000 HP• Intermittent rating for drawworks applications of 1250 HP• Continuous rating is at 750 VDC, 57 Amps, 1050 Amperes, 1040 RPM

C75ZB(E)-F Reconditioned DC Hi-Torque Drilling Motor

• Continuous rating for mud pump and rotary table applications of 1085 HP

• Intermittent rating for drawworks applications of 1320 HP

• Continuous rating is at 750 VDC, 1150 Amperes, 965 RPM


Models

C75YZB(E) New DC Hi-Torque DC Drilling Motor

• Continuous rating for mud pump and rotary table applications of 1085 HP• Intermittent rating for drawworks applications of 1320 HP• Continuous rating is at 750 VDC, 1150 Amperes, 965 RPM


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Differences Between ModelsThefollowingtableliststhedifferencesbetweenthevariousmodelsofJOLIETEquipmentCorporationmotors.

Model DifferencesC75ZB / HReconditioned 1000HP DC Drilling

C75ZB Horizontal Series; left-hand terminal boxC75ZH Horizontal Series; right-hand terminal box

C75ZE / KReconditioned 1000HP DC Drilling

C75ZE Horizontal Shunt; left-hand terminal boxC75ZK Horizontal Shunt; right-hand terminal box

C75ZB-F / HReconditioned DC Hi-Torque Drilling Motor

C75ZB-F Horizontal Series; left-hand terminal boxC75ZH-F Horizontal Series; right-hand terminal box

C75ZE / K-FReconditioned DC Hi-Torque Drilling Motor

C75ZE-F Horizontal Shunt; left-hand terminal boxC75ZK-F Horizontal Shunt; right-hand terminal box

C75YZB / HNew DC Hi-Torque DC Drilling Motor

C75YZB Horizontal Series; left-hand terminal boxC75YZH Horizontal Series; right-hand terminal box

C75YZE / KNew DC Hi-Torque DC Drilling Motor

C75YZE Horizontal Shunt; left-hand terminal boxC75YZK Horizontal Shunt; right-hand terminal box

Models

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General SpecificationsLocationofmainconnectionboxes(lookingatcommutator-end)

• Connectionboxonleftside,modeldesignationswithsuffixletterB and E.

• Connectionboxonrightside,modeldesignationswithsuffixletterH and K.

Motor Part / Motor Characteristic Specification Data Max. Permissible Speed Motors 2300 RPM Max. Permissible Vibration (Commutator End) 0.002 in.Resistance at 25°C (ohms) Min. Max. Armatures Models: C75ZE(K), C75ZE(K)-F, C75YZE(K) 0.00749 0.00800 Models: C75ZB(H), C75ZB(H)-F, C75YZB(H) 0.00749 0.00800 Exciting Fields Models: C75ZE(K), C75ZE(K)-F, C75YZ(K) (With Cables) 1.13 1.22 Models: C75ZB(H), C75ZB(H)-F, C75YZB(H) (With Cables) 0.00513 0.00549 Commutating Fields Models: C75ZE(K), C75ZE(K)-F, C75YZE(K) (With Cables) 0.00431 0.00492 Models: C75ZB(H), C75ZB(H)-F, C75YZB(H) (With Cables) 0.00431 0.00492Carbon Brushes Type T900 Size 3/4 x 2-1/4 x 2 in. Minimum Brush Length (length at which brush becomes inoperative – measure brush on the longest side)

1-3/32 in.

Spring Pressure on Brush, Preset 10-12 lb.Brushholder Clearance to Commutator 1/16-3/32 in. Clamp Bolt Torque 225-250 lbs-ftCommutator Side Mica Thickness 0.060 in. Slot Depth 0.047 in.Undercutting Saw Width 0.063 in. Diameter 1.000 in.Commutator Diameter New 16.625 in. Worn (minimum permissible) 15.375 in. Riser Width (minimum permissible) 0.625 in.

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General S

pecifications

Motor Part / Motor Characteristic Specification DataDust Groove Width 0.250 Depth 0.125Concentricity – New Commutator Total Indicated Runout, TIR 0.001 in. Variation of Indicator Runout within any Group of 20 Bars 0.0004 in. Variation of Indicator Reading between any Two Adjacent Bars 0.0001 in.Concentricity – Used Commutator (Resurface if runout exceeds 0.010 TIR or 0.003 within any group of 6 bars) After Resurfacing, TIR 0.001 in. Bar-To-Bar Test (500 V) Voltage Variation Bar-To-Bar ± 5%Armature Balance Commutator-end 12 grams (0.42 oz.) Drive-end 10 grams (0.35 oz.)Armature Bearings Radial Clearance, Assembled Min. Max. Drive-end 0.005 in. 0.009 in. Commutator-end (Roller Bearing) 0.003 in. 0.006 in. Commutator-end (Ball Bearing) 0.0005 in. 0.0035 in.Runout Measured from Shaft to Outer Race

Drive-end 0.004 in. Commutator-end 0.003 in.Pole Bore Diameter (measured at center of pole) Motors Min. Max. Exciting Poles 19.626 in. 19.663 in. Commutating Poles 19.956 in. 19.988 in.Impedance Test Coiled Frame Without Armature (With non-magnetic retainers) Pass 60 Hz Through Voltage Drop Exciting Fields Amps. Min. Max. Models YZB / F, YZH / F 24 13.1 15.6 Models YZE / F, YZK / F, YZB / F, YZH / F 0.5 59.0 66.6 Commutating Fields Models YZB / F, YZH / F 24 7.3 8.1 Models YZE / F, YZK / F, YZB / F, YZH / F 24 7.3 8.1

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Motor Part / Motor Characteristic Specification DataLubrication – Armature Bearings Grease Capacities Drive-end 32.5 oz. Commutator-end Models YZE/K, YZB/H, ZE/K-F, ZB/H-F, ZE/K, ZB/H 12.25 oz. Model YZF, ZF-F, ZC, ZF 31.8 oz. Lubricant Shell Cyprina RAWeights (approximate) Complete 6720 lb. Armature Only 2100 lb.High-Potential Test 60 Hz, a-c, to ground for one minute (All Windings) (Volts) New or Rewound Armature 3500 V Reconditioned 2000 V Minimum Megohmmeter Reading (ohms) 2 megohms

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General Operation Information General O

peration Information

JOLIETdrillingmotorsareusedtopoweroffshoreandland-baseddrillrigsusedbytheoilandgasindustry.Forthespecificratingsforeachmotor,seeModels.

General FeaturesInprovidingthebestelectricmotorsandrelatedtechnology,JOLIETdrillingmotorsinclude:

• Alargearmatureslotconfigurationprovidinga heavycoppercrosssectiontoincreasethemotor’s capabilityforcarryinghighcurrentloads.

• Aspiralgroovecommutatorwhichhelpscoolthe commutator(high-torquemodels).

• Highcurrentexcitingandcommutatingpolefield coils.

• Improvedinternalairflowforincreasedcooling.

• Anopenpinion-endframeheadforincreased cooling(high-torquemodels).

• Theabilitytooperatethedrillingmotorineither rotationaldirection.

• Theabilitytomountthepressurizedcontrolboxoneithersideofthemotor.Formoreinformation,seeChanging the Position of the Connection Box.

ATEX Certification Safety ConsiderationsThefollowinglistprovidesthespecialconditionsyoushouldfollowforsafeuseofanyJOLIETdrillingmotor:

1. Youmustfollowthesepressurizationand purgingrequirements:

a. Aminimumairflowof3000ft.3/min. (85m3/min.).

b. Aminimumpurgetimeof5minutesplus10 secondsforeveryadditional35.3ft.3(1m3) ofducting.

c. Aminimumlowpressuresettingof2in.of WG(5mbar).

2. Itisyourresponsibilitytoensurethatany certifiedancillariesusedinconjunctionwiththe motormeettheconditionsfortheiruse.

3. Youhaveconnectedthewindingresistance temperaturedetectors(RTD’s)eitherintointrinsi- callysafecircuits,oryouhavetheminterlocked withthepurgingsystemsothattheycannotbe energizeduntilthemotorhascompletedapurge cycle.

4. TheSpecialConditionsforsafeuseorthe ScheduleofLimitationsasappropriatefor Certificates.

5. Whenyouactivatetheauxiliaryswitch,thatisyouhavepinnedthemotors,ACvoltagemaystillbepresentonthedeviceterminalboards.Thespaceheater(240VAC)andblowerunit(460or575VAC)maystillbeonunlessyouhavepreviouslyswitchedthemoff.Thereisadangerofasevereelectricalshockifyoudonotswitchoffthespaceheaterandblowerunitwhenyouactivatetheauxiliaryswitch.

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Safe Electrical Parameters – Shunt WoundThefollowingtableliststhesafeelectricalparametersforshuntwoundJOLIETdrillingmotors.

Category RatingShaft horsepower 1130 Armature Volts DC 750 Armature Amps DC RMS 1185Shunt field Amps 60Full Load RPM 1040Maximum RPM 2300Maximum ambient temperature 40°CInternal free volume (cu. ft.) 6.6Minimum purge / cooling flow rate

3000 CPM

Minimum purge time 5 min (plus 10 seconds for each cubic meter of duct)

Minimum overpressure at enclosure

2.00 in. WG

Minimum differential pressure through frame

6.00 in. WG

Incoming cable maximum operating temperature

125°C

Safe Electrical Parameters – Series WoundThefollowingtableliststhesafeelectricalparametersforserieswoundJOLIETdrillingmotors.

Category RatingShaft horsepower 1085Armature Volts DC 750Armature Amps DC RMS 1150Full Load RPM 965Maximum RPM 2300Maximum ambient temperature 40°CInternal free volume (cu. ft.) 6.6Minimum purge / cooling flow rate

3000 CPM

Minimum purge time 5 min (plus 10 seconds for each cubic meter of duct)

Minimum overpressure at enclosure

2.00 in. WG

Minimum differential pressure through frame

6.00 in. WG

Incoming cable maximum operating temperature

125°C

WarningsToensureyoursafety,followthefollowingwarningswhenworkingonJOLIETdrillingmotors:

1. Poorlygroundedequipmentcanbeashockhazard.Youmustgroundtheequipmentbeforeuse.Thereisapotentialforseriousorfatalinjuryfromelectricalshockifyoudonotproperlygroundelectricalequipment.

2. Usingcompressedairforcleaningpurposescanraisedebrisandflyingparticles.Compressedairmayalsocontainmoisture;donotuseonenergizedmotor.Wearsafetyglassesandotherpersonalprotectiveequipmentwhenusingcompressedairforcleaningpurposes.Flyingdebrisandparticlesmayalsopresentahazardtopersonnelintheimmediatearea.Improperprotectioncanresultinseriousinjury.

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General O

peration Information

3. Removingorreplacingbrusheswhilethe equipmentisenergizedorrotatingcanbeashockhazard.Donotremoveorreplacebrusheswhiletheequipmentisenergizedorrotating.Electricshockcancauseseriousorfatalinjury.

4. Testingcanbeashockhazard.Electricshockcancauseseriousorfatalinjury.Takeproperprecautionsduringtesting.

5. Resurfacingoperationscanraisedustand flyingparticles.Wearsafetyglassesanda respiratorforprotectionfromdustandflying particlesduringresurfacingoperations.Improper protectioncanresultinseriousinjury.

6. Highpotentialtestingcanbeashockhazard. Electricshockcancauseseriousorfatalinjury. Takeproperprecautionsduringhighpotential testing.

7. Brazingrequiresextremelyhightemperatures. Wearsafetyglassesandleatherglovesatall timesduringbrazingoperations.Improper protectioncanresultinseriousinjury.

8. UsingMEKasacleaningsolutioncanbea healthhazard.Donotinhalethefumes.Use MEKonlyinawell-ventilatedarea.Take adequateprecautionstoprotectyoureyes, skinandhands.Improperprecautionscan resultininjury.

Youwillseethesewarningsthroughouttheservicecatalogasareminderoftheseconditions.

Closed Cooling SystemsYoucanmountJOLIETdrillingmotorsinatotallyclosedcoolingsystemwithanairtowaterheatex-changer.Ifyouusethisalternatecoolingsystem,ithasthefollowingrequirements:

• Acleanableairfilter

• Aseawaterheatexchangerthatrequires50 GPMof22°Corcoolerwater

• A15horsepowercentrifugalblower

• A240VAC(440,460or575)volt,60cycle 3-phaseexlosion-proofmotorwithassociated ductingandaccessories

Ifspecifiedandfittedwithproperaccessories,themotorsareCertifiedforHazardousAreas.Whenutilizingdifferentaccessories,thesemotorsarealsoavailableCertifiedforHazardousAreaswithoutatotallyclosedcoolingsystem.

Special Handling RequirementsYoumustusespecialliftingdeviceswhenhandlingJOLIETdrillingmotorswiththeircoolingsystemsattachedtoavoiddamagingthecoolingandpurgesystems.Youmustnotlifttheentiremotorassemblywiththeliftingeyesontheheatexchangerorblowerassembly.Thiscandamagethecoolingandpurgesystem.

Grounding

s WARNING s Poorly grounded equipment can be a shock hazard.

You must ground the equipment before use. There is a potential for serious or fatal injury from electrical shock

if you do not properly ground electrical equipment.

Youmustprovidegroundingforthefollowingequip-menttoprotectyourpersonnelfrompotentiallyhazard-ousconditions:

• Themotorframestoprotectyourpersonnelfrom electricshockshouldtherebeaninsulation failureinthemachine.

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• Theconductorsbetweenthemachineframe andtheadjacentsupportingstructureonwhich apersonmaybestandingwhiletouchingthe machine.

Note: This type of ground connection is referred to in elec-trical standards as “equipment grounding” or “enclosure grounding” which is not to be confused with “system” or “cir-cuit” grounding. Drilling drive systems typically do not have intentional circuit ground connections, except through high impedance detectors.

• Thedrillingunitsonwhichtheconstructionofthe unitand/ortheinstallationofthemachinesdonot inherentlyinsurepositivegroundingofthe equipment.

Thisisrequiredinportable(modular)platformrigsandlandrigswhichdonotalreadyhavegroundcablestoallmachinerystructures.Offshorerigswithequip-mentfastenedtothedecksbyboltingorweldingshouldnotrequireadditionalgrounding.(Forfurtherinformationsee:ABSRulesforBuildingandClassingSteelVessels,Section35.9.6,andIEEEStandard45-1977,RecommendedPracticeforElectricalInstallationsonShipboard,Section21.4.)

Thefollowingprocedureprovidesthestepstofollowforeffectivelygroundingthemotor.

Note: We provide a 0.375 in. grounding stud on one of the mounting feet you can use to connect the ground cable to the drilling motor. Refer to the appropriate Outline drawing for the stud location.

1. Preparea4/0sizeorlargercoppercablegroundconductorlongenoughtorunfromthemotorframetoeitheranexistinggroundconductorsystemorasuitableequipmentgroundpointasdefinedbytheNationalElectricalCodeArticle250orotherapplicableregulation.(Forfurtherinformation,see:NationalElectricalCode,1978Edition,Table250-95.)

2. Checkthatthesystemgrounddetectorisconnectedtothecommongroundpointfortherigandmaketheconnectionifnecessary.

3. Obtaintwocableterminalstofit:

• Thegroundcableonthedrillingmotorendlargeenoughforthe0.375diametergroundingstud.

• Theoppositeendofthecableandits groundingconnection.

4. Installbothcableterminalstothecable.

5. Removepaint,rustandoilfromthesurfacesto whichthecablesaretobeattached.

6. Connectbothcableterminalssecurely.

7. Usingadigitalohmmeter,checkthattheconnec- tionsaresolid,lowresistanceconnectionsfrom thecableconductortothegroundpointandto themotorframe.

Themeterreadingshouldbe0.2ohmsorless.

LubricationYoudonotneedtolubricateanyJOLIETdrillingmotordesignedforhorizontaloperationbetweenoverhaulperiods.Formoreinformation,seeOverhaul.

Special ToolsThefollowingtableliststheitemsyourequiretomaintain,repairandoverhaulJOLIETdrillingmotors:

Tool PartMegohmmeter 1,000 volts Fluke or equivalentVoltmeter MultimeterResurfacing Stones• Medium Grade 8828492P11• Finish Grade 8828492P8Brush-Seater Stone (White) 106X98Hub Assembly Gauge 41D790941G1Hub Puller (less pump) 41B535703G1Pump (for above) 8843947G1

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Caution: All models of JOLIET drilling motors require cooling. The cooling air should be free of combustible gases which could be ignited by a spark. If you must run your equipment in these conditions, make sure you provide an adequate supply of non-contaminated cooling air. If necessary, use a drill motor with provisions for ducting suitable cooling air and containing other protective equipment such as spark arrestors.

Monthly InspectionsThefollowingtableliststhetasksyoushouldperformaspartofyourmonthlyinspection.

Part Standard Operation Monthly Service Exterior The exterior should be clean and damage-

free.• Inspect the exterior of the machine, including cables, for

damage and replace as required.• Clean the exterior using clean, dry compressed air.

Covers, Seals, Latches The covers, seals and latches should be intact and operate properly.

• Remove the inspection covers and ensure covers fit properly and cover latches work properly.• Clean the interior using clean, dry compressed air and blow the dirt and carbon dust from the machine. • Check exterior covers to ensure seals are intact; replace missing or damaged covers or seals as required.

Brushholders and Brushholder Sleeves

Brushholders and brushholder sleeves should be damage free and be installed securely.

• Inspect the brushholders for damage. If you must replace brushholder(s), see Brushholders, Working with the motor parts for more information. • Use a clean, lintless cloth and wipe dirt and grease from the Teflon® brushholder sleeves; if necessary, use a cleaner such as MEK (methyl ethyl ketone) to clean the sleeves. Be sure to follow standard safety precautions for handling a volatile solvent.• Inspect sleeves for cracks and thin spots caused by flashovers. Replace any damaged brushholder or one having a damaged sleeve. • Inspect the brushholder cables and make sure all terminal bolts and all brushholder clamp bolts are tight.

Inspections Inspections

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Part Standard Operation Monthly Service Brush Spring The brush spring should move freely and

brush spring pressure should be within accepted pressure value limits.

• Check for free movement of the spring assembly by lifting the brush pressure fingers to the “toggled-up” position.• Inspect brush springs for obvious failure or damage. • Check brush-spring pressure by comparing spring pressure with a spring known to be good. For brush spring-pressure value, see General Specifications.

Brushes Brushes should be long enough to last until the next inspection, be free of excessive wear and be positioned correctly.

• Check brushes for wear: • Lift the brush spring, remove the brush and measure

the brush length on the longest side from the top of the carbon.

• Ensure brushes have enough length to last until the next monthly inspection. For more information on brush length, see General Specifications.

• Check brushes for surface integrity: • Inspect all brushes to ensure the brushes are not

chipped or broken. • Inspect brush shunts to ensure they are not frayed or

broken.

Note: Brushes that are chipped, burned or rough-faced may indicate that the commutator needs resurfacing.

• Check brushes for positioning and connections: • Move the brushes up and down in their carbonways

to ensure brushes slide freely. • Check the brush shunts to be sure they are not

twisted or out of position. • Make sure all brush-shunt terminal connections and

all brushholder cable connections are tight.

Recommendation: We recommend you replace a brush that shows any damage of any kind. We also recommend that if one brush is showing wear, that you change all brushes at the same time. For more information on installing brushes, see Brushes, Working with the motor parts.

Inspections

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Part Standard Operation Monthly Service Commutator The commutator should be clean, smooth,

glossy and free of high mica, high bars, flat spots or rough surfaces.

• Inspect the commutator for possible flashover damage. • Verify that the commutator is perfectly round; if there are indications that the commutator is out-of-round (such as variations in the width of the ridge between brush paths), check the concentricity of the commutator with a dial indicator. For more information on the condemning limits for concentricity, see General Specifications. If the commuta-tor requires grinding, see Commutator, Working with the motor parts and Resurfacing.

Creepage Band The creepage band should be clean and installed tightly on the commutator cap.

• Clean the creepage band (located on the commutator cap) with a clean cloth dipped in an approved solvent. • Inspect the band for possible flashover damage. • Ensure the creepage band is installed tightly on the commutator cap.

Flash Ring The flash ring should be clean and varnish- free.

• Examine the flash ring for possible flashover damage. • Wipe the flash ring clean with a clean cloth dipped in an approved solvent.

Insulation The insulation should have a normal resistance level and not show cracking.

• Measure the insulation resistance with a megohmmeter; if the reading is low, inspect the insulation to determine if the cause is insulation failure or excessive moisture.• Correct the cause of the low readings before returning the motor to service. • Inspect all accessible parts of the field coil insulation for cracking and evidence of overheating.

Power Cables The power cables should appear in good condition.

• Inspect the power cables for signs of excessive heating, poor insulation or mechanical damage. • Ensure all power cable terminals are secured tightly.

Mounting Bolts All mounting bolts should be tight. • Check all mounting bolts to ensure that they are maintaining the correct bolt load.

Air Filters If applied, air filters should be free of containments.

• Inspect the air filter in the cooling system assembly. • Clean or change the filter as needed at each inspection.

Inspections

20

Inspection prior to OperationYoushouldperformthefollowinginspectionsbeforebringinganewJOLIETdrillingmotoron-line:

• Removerodentguardsand/orducttapeoverthe airexitportsatthepinion-endofthemotor.

• Removeandreversetheshipping/exhaustcover priortooperation.

• Verifythatallnecessaryequipmentblowersand ductworkareinplaceandingoodcondition.

• Removetheprotectionmaterialappliedtothe commutatortopreventdamagewhilethemotor wasintransit.

• Removetheyellowarmaturelockingboltinstalled topreventmovementduringshipping,replaceit withthesuppliedbolts,andre-torquetheboltto 100-120lbs-ft(seeFigure1below).

CAUTION: You must provide adequate cooling for your JOLIET drilling motor. Without adequate cool-ing, you could cause the equipment to overheat which in turn could shorten equipment life and negatively affect warranty coverage.

Inspections for Closed Cooling SystemsThefollowingtableliststhetasksyoushouldperformwheninspectingclosedcoolingsystems.

Time Period ActivitiesEvery 7 days Check the three zinc anodes in the heat

exchanger; you should replace them as soon as they start weeping water.

Every 30 days Check for air or water leaks; tighten all connec-tions which may have become loose during operation.

Every 90 days Inspect the carbon dust filter element. If required, clean the element with compressed air, water or steam. Let the dust filter element dry completely before you reinstall. Do not clean using chemical solvents.

Semi-Annual Inspections1. Performtheinspectionoperationslistedunder MonthlyInspections.

2. Checktheclearancebetweenthebrushholders andthecommutatorsurface.Forinformationon brushholderclearancedimensions,seeGeneral Specifications.

3. Ifthedimensionsdonotmeettheminimumrequirements,adjustthebrushholderclearance.Formoreinformation,seeBrushholders and Brushes,Working with the motor parts,Adjusting the Brush-holder Clearance.

Inspections

Yellow Armature Locking BoltsFigure1

21

Recommendation: We recommend that you perform a basic motor overhaul at least every two years, or 18,000 operating hours of normal operation. Exactly when you perform an overhaul can vary, depending on the condi-tion of the machine and your overall operation.

Thissectioncoversprocedurestodisassemble,clean,inspect,repair,reassembleandtestthemachine.

Testing the Motor before DisassemblyThefollowingtableliststhetestsyoushouldperformbeforedisassemblingthemotor.

Test DescriptionMegohmmeter Test Determine the condition of the

insulation by:1. Lifting the brushes.2. Performing a megohmmeter

test on the armature windings and field coils.

If you receive a reading of less than 2 megohms you should check the quality of the insulation, whether the insulation has excessive dirt accumulation or moisture.

Bar-To-Bar Resistance Test Test for open or short-circuited armature coils by:1. Passing a regulated d-c current

through the armature coils.2. Reading the voltage drop

between the commutator bars with a millivoltmeter.

If you receive a reading that varies more than ±5% from the average value, there is a defective or short-circuited coil.

Disassembling the MotorRemoving the Hub

Useasuitablepullerwhenremovingahub.

Recommendation: We recommend a puller similar to Part 41B535703G1. This simple, efficient hydraulic puller uses the float method. A complete unit consists of a pump kit, a backing plate, an adapter, a felt ring and a bolt.

Caution: Do not heat the hub before pulling it or use steel wedges between the hub and bearing cap.

1. Removetheset-screwplugfromthetappedholeintheendoftheshaft.

2. Withthefeltringinplace,screwthebackingplatetotheendoftheshaftbyhand.Makethescrewastightaspossible.Toprovidesufficientclearanceforthehubtopopoff,backoffthebackingplatetolineuptheslotwiththetappedholeintheendoftheshaft.

3. Screwthepressure-fittingadapterintotheholeintheshaftuntilitseatsatthebottom.

4. Attachthepump.Screwtheconnectorononeendofthepressuretubeintotheadapter,andtheotherendintothepump.

5. Closethehandreliefvalveandworkthepumphandletoforceoilintothegrooveinthearma-tureshaftunderthehub.Whenyouhavebuiltupsufficientpressure,thehubwillpopofftheshaftandbestoppedbythefeltwasherandbackingplate.

Note: The capacity of the pump is 40,000 psi. It holds suf-ficient oil to remove eight to ten hubs. To ensure you have sufficient oil, you should check the level at each use. When required, remove the filling plug and refill with SAE-10 lubricating oil.

Motor O

verhaul

Motor Overhaul

22

6. Openthereliefvalveandperformthefollowing steps:

a.Disconnectthepumpfromtheadapter.

b.Removetheadapterandbackingplate fromtheshaft.

c.Liftoffthehub.

7. Whenthehubisoff,reinserttheplugtoprevent cloggingthehole.

CAUTION: When either lifting the armature in the vertical position or turning the armature to a horizontal position, you should take special precautions to avoid damage to the armature end-windings, bearings or bearing fits, and the com-mutator.

Removing the Armature From the Frame Ifequippedwithcoolingsystemcomponents,removethembeforeproceeding.(Refertotherespectivesupplier’sinstructionsasnecessary.)

Beforeturningthemachinefromhorizontaltovertical(orvice-versa),attachthearmaturelockingarrange-menttopreventthearmaturefrommovingaxially.Removethearmaturelockingarrangementbeforeoperatingthemachine.

s WARNING s When using compressed air for cleaning purposes, flying debris and particles may present a hazard to personnel in the immediate area. Personnel should be provided with, and trained in the use of, personal

protective equipment as specified by applicable federal or state safety regulations.

1. Cleantheoutsideoftheframe,usingcom- pressedair,asteam-jennyorcleaningsolvents, toremoveaccumulateddirt.

2. Removethecouplinghubfromtheshaft,ifnot alreadyremoved.

3. Removethecommutatorcovers.Disconnectand removeallbrushes,andwrapheavypaper aroundthecommutatorforprotectionduring handling.

4. Removeboltsandwashers(41)whichholdtheinnerandouterbearingcapstothecommutator-endframehead.Takeoffouterbearingcap(42)andgasket(44).

5. Turnthemachineonendonastand,commuta-tor-enddown,andlevelitsothatthearmaturecanbeliftedverticallyoutoftheframewithoutdamagingthebearings,commutatororbrushholders.

6. Screwthreeguidepinsintothecommutator- endinnerbearingcap(46)tohelpguidethe armatureoutoftheframe.Screwaliftingbail ontothedriver-endoftheshaft.

7. Removedrive-endframeheadboltsandwash-ers(8)andinsertjackscrewsinthethreadedholesprovidedintheframehead(7).

8. Lineupthehoistcablewiththecenterlineofthearmaturebeforeengagingthehookintheliftingbailontheendoftheshaft.Engagethehookandliftslightly.Withsufficientstrainonthehoistcabletotaketheweightofthearmatureofftheframehead,jackthedrive-endframeheadloose,andliftthecompletearmatureassemblyoutoftheframe.DONOTDAMAGETHECUMMUTATOR.

CAUTION: Special precautions should be taken to avoid damage to the armature end-windings, bear-ings or bearing fits, and the commutator when lift-ing the armature in the vertical position or turning the armature to a horizontal position.

9. Placethearmaturehorizontallyinanarmature saddleforbearingdisassembly.

10. Removethetwosetscrewsfromthesecuring nutatthecommutator-endoftheshaft.

11. Removethenutfromtheendoftheshaftusinga spannerwrench.

12. Installpullertoolandpulltheinnerraceofroller bearing(50)fromthecommutator-endofthe shaft.Sleeve(49)willcomewiththebearing.

13. Removeinnerbearingcap(46).

23

14. Usingpullertool,pulltheoutersleeve(1)from thedrive-endoftheshaft.Thesleevehas tappedholesforapplyingthepuller.Heatmay beapplied.

15. Removeboltsandwashers(3,4),andthen removeouterbearingcap(2)andgasket(5).

16. Slideframehead(7)offtheshafttogetherwith theouterraceandrollersofbearing(6).The innerracewillremainontheshaft.

17. Pulltheinnerbearingraceofftheshaftwith puller.

18. Removeslinger(9)andinnerbearingcap(10) withpullerbyinsertingthefourpullerbolts intothetappedholesininnerbearingcap(10).

19. Ifnecessary,removeinnersleeve(20)withpuller.

20. Presstheouterbearingraceandrollersfrom theframeheadwithanarborpress.

Note: Before pressing the drive-end outer bearing race out of the framehead, observe and record the number on the face of the race. Mark the framehead in relation to the number. Rotate 90 degrees upon reassembly. After removal, mark the date (with an electric pencil) under this number to indicate that this position has been used. Reassemble the bearing with another number opposite the mark. Etch the numbers 1, 2, 3 and 4 (spaced 90 degrees apart) on the face of race with an electric pencil. Locate number 1 opposite the mark on the framehead and mark it with the date.

21. Ifnecessarytoremovethecommutator-end framehead(45),turntheframecommutator- endupandremoveboltsandlockwashers (43).Useboltsintheframeheadjack-out holestobreakthefitandremove.

Testing after OverhaulTesting Series Models

RefertovendorpublicationsfortestingthecoolingsystemsonmodelYZB(H).Afterthemotorhasbeenreconditionedandreassembled,performthefollowingteststoensureitoperatesasexpected.

InthistestyouwillconnectthemotortoaDCarc-weldinggeneratorandrunthemachineseries-con-nectedwithoutloadat900rpminordertomeasurebearingtemperatures.

1. Useaputty,suchasDuxsealfromJohnsManvilleCompany,toholdthethermometersonthedrive-endandcommutator-endouterbearingcaps.Forbestresults,thethermometersshouldcontactthebearingcaps.

2. Seatthebrushesandrunfortenminutesat900 rpm.Theframetemperatureshouldnotrise greaterthan25°C.

3. Withthemachinerunninguptospeed,measure thevibration.Thevibrationshouldnotexceed 0.1in/seconthecommutator-end.Ifthevibration exceedsthisvalue,rebalancethearmature.

4. Checkthecommutatorforroughnessandmake surethebrushesareridingproperly.

5. Checkfornoisybearingsusingalisteningrod.

6. Stopthemachineandmountanindicatoronthe frame.Whileturningthearmaturebyhand, measurecommutatorrunout.Therunoutshould notbegreaterthan0.001in.

7. Measurethefieldimpedance.With60HzACand24amperesthrougheachfield,measurethevoltagedropacrosstotalexcitingandcommutat-ingfields.Forvoltagelimits,seeGeneral Specifications.

s WARNING s Testing can be a shock hazard. Electric shock can

cause serious or fatal injury. Take proper precautions during testing.

8. Performahigh-potentialtesttothewindings oftheassembledmachine.Fordetailsonthe highpotentialtest,seeGeneral Specifications.

s WARNING s High potential testing can be a shock hazard. Electric shock can cause serious or fatal injury. Take proper

precautions during high potential testing.

Motor O

verhaul

24

Testing Shunt Models RefertovendorpublicationsfortestingthecoolingsystemsonmodelYZE(K).Afterthemotorhasbeenreconditionedandreassembled,performthefollowingteststoensureitoperatesasexpected.

Afterthemotorhasbeenreconditionedandreassem-bled,performthefollowingteststoassureitwilloperatesatisfactorily.

Youconductthistestwiththemotorventilatedat2800CFMatthecommutatorchamberwitha10HPblower.

1. ConnectthemotortoaDCweldinggenerator. Refertoconnectiondiagram(Figure3)for connections.

2. Runthemachinebyseparatelyexcitingtheshuntfieldfroma125VDCsource.Fromanothersourceofpower,applyvoltagetothearmaturecircuituntilyouhavereachedthedesiredspeed.

3. Holdseparatefieldexcitationat57.5amperes.VarythearmaturevoltagetoobtaintherequiredRPM.Atapproximately700terminalvolts(noload),thespeedwillbe900RPM.

4. Ifthemotorisnotventilated,performthe followingtest:

a. Holdtheseparatefieldexcitationat10to15amperes.VarythearmaturevoltagetoobtaintherequiredRPM.Atapproximately338terminalvolts(noload),thespeedwillbe900RPM.

b. Runthemotorforfiveminutesat450RPM.

c. Increasethespeedto900RPMandrunfortwohours.Thebearingtemperaturesshouldnotexceed70°C(158°F).Rununtilthebearingtemperatureremainsconstantfor30minutes.

d. Increasethespeedto1300RPMandholditwhileperformingSteps2,3and4.Thenshutdownthemotor.Donotexceed1300RPM.

e. Measurethevibrationwhenrunningthemotoruptospeed.Thevibrationshouldnotexceed0.1in/secIfthevibrationexceedsthisvalue,rebalancethearmature.

f. Checkthecommutatorforroughnessand makesurethebrushesareridingproperly.

g. Checkfornoisybearingsusingalistening rod.

h. Stopthemotorandmountanindicatoron theframe.Turnthearmaturebyhandand measurecommutatorrunout.Therunout shouldnotbegreaterthan0.001in.

s WARNING s Testing can be a shock hazard. Electric shock can

cause serious or fatal injury. Take proper precautions during testing.

i. Measuretheinsulationresistanceofthewindingswithamegohmmeter.Iftheresis-tancemeasuresmorethanonemegohm,applyanAChighpotentialtesttogroundforoneminute.Fordetailsonthehighpotentialtest,seeGeneral Specifications.



25

CleaningToensureproperoperation,werecommendthefollowingmethodsforcleaningtheyourdrillingmotor.

Steam Cleaning Youcanusethismethodforcleaningbothinsulatedandmetalparts.

1. Usesteamincombinationwithacommercial non-causticcleaner.

CAUTION: Never use caustic soda solution on the armature or coiled frame.

2. Suspendthepartinapositionwhereitcanbein thedirectflowofsteamfromthehosefromall directions.

3. Rinseallresiduefromthepartsusingamixture ofcleansteamandwater.

4. Bakeinsulatedpartsforatleast8hoursat 150°C(302°F)toremoveallmoisture.

Vapor Degreasing Youcanusethismethodjustformetalparts.

1. Bringthecleaningsolutiontoaboil,andallowthevaporlineinthetanktorisetothecondensercoilsatthetopofthetank.

2. Keepthevaporizedcleaningsolutionatabout 120°C(248°F).

3. Lowertheparttobecleanedintothevapor-ladenatmosphere,sothevaporwillcondenseonthepart.

4. Tospeedtheremovalofheavydirtaccumula-tions,sprayhotsolutiondirectlyfromthetankontothepartbeingcleaned.Thetemperatureofthesolutionmustbekeptbelowitsboilingpoint.

5. Removethecleanedpartfromthedegreaser.

6. Drainandcoolthepart.

Cleaning Anti-Friction Bearings/Shaft Tapers/Bearing Fits Youcanuseacleaningsolutionthatleavesanoilfilmtoprotectfinishedsurfacesfromrust.Kerosene,petroleumspiritsorotherpetroleum-basedcleanersprovidelimitedprotectionforthesesurfaces.

Cleaning

26

The Brushes and BrushholdersReplacing the Brushes

Youshouldcheckthebrushspringpressurebeforereplacingbrushes.Thebrushspringpressureispre-setandnon-adjustableforthebrushholdersusedonthesemachines.Ifyouhaveabrushholderthatiseitherdamagedorhasalowspringpressure,youshouldreplaceitbeforeinstallingnewbrushes.Youmeasurespringpressurewitha20-lb.springscalepullingradiallyonthebrushpressurefingeroverthecenterofeachbrush.Forinformationonlimits,seeGeneral Specifications.

Recommendation: When replacing brushes, we recom-mend you use only the brush grades listed in the General Specifications. If you mix brush grades in the same motor or change brushes to another grade you can seriously affect commutation, surface film, commutator and brush life.

Removing the Brushes

Usethefollowingproceduretoremovebrushes.

1. Removethecommutatorinspectioncovers.

2. Disconnectthebrushshuntfromtheterminalscrewlocatedonthebrushholderbody.

3. Liftthepressurefingerawayfromthebrushtothetoggled-upposition.

4. Removethebrush.

5. Usedry,compressedairtoblowthecarbon dustfromthecarbonway.

s WARNING s Using compressed air for cleaning purposes can raise

debris and flying particles. Wear safety glasses and other personal protective equipment when using compressed air for cleaning purposes. Flying debris and particles

may also present a hazard to personnel in the immediate area. Improper protection can result in serious injury.

Installing the Brushes

Usethefollowingproceduretoinstallbrushes.

1. Insertanewbrush;ensurethatthebrushslidesfreelyinthecarbonway.

2. Carefullylowerthespring-loadedbrush pressurefingeronthebrush.

Caution: Do not allow the finger to snap down on the brush as this can chip and damage the brush.

3. Attachthebrush-shuntterminalstothe brushholderbodyunderthescrewsprovided.Arrangethebrushshuntstrandssothattheyclearthepressurefingers.

4. Cleantheterminalsandtightentheterminal screw(s).

Caution: Make sure brush shunts are not posi-tioned under the pressure fingers.

5. Checkandtightenallbrushholdercable connections.

6. Seatthenewbrusheswithawhiteseaterstone.

7. Installthecommutatorcoversonthemotorandcheckforproperfitandlatchoperation.

Replacing the Brushholders

Usethefollowingproceduretoremovethebrushholder.

1. Removebrushesfromthebrushholders.

2. Coverthecommutatorwithheavypaper.Youwillleavethepaperonthecommutatortoprotectituntilyouhaveinstalledthenewbrushholder.

3. Disconnectthecablefromthebrushholder(s)youareplanningtoremove.

4. Removethebolt,washerandbrushholderclamp.

5. Liftthebrushholderoutoftheframe.

Working with the Motor Parts

27

The B

rushes and Brush H

older

Installing the Brushholders

Usethefollowingproceduretoinstallthebrushholder.

1. Positionthebrushholderintheframewiththebrushholderstudsrestingintheclampsurfacesofthebrushholdersupport.

2. Installtheboltandwasher.Tightentheboltbutdonottorquetheboltuntilyouhavedeterminedthebrushholder-to-commutatorclearance.Formoreinformation,see Adjusting the Brushholder Clearance.

3. Afteryouhavesetthebrushholderclearance,connectthebrushholdercableandremovetheprotectivepaperfromthecommutatorsurface.

4. Checkthebrushestoinsurethattheyexceedtheminimumbrushlengthdimensionandarefreeofanydamage.Youcanreusethemiftheyarelongenoughandarenotdamaged.Ifnot,youshouldreplacethemwithnewbrushes.

Adjusting the Brushholder Clearance

Usethefollowingproceduretoadjustthebrushholderclearance.

1. Removethebrushes.

Caution: Do not allow the brushholder to touch, bump or rest on the commutator.

2. Inserta1/16in.fiberspacerbetweenthebottomofthebrushholderandthecommutator.Youmayhavetoloosenthebrushholderifthegapislessthan1/16in.

Caution: Do not use a metal spacer.

3. Loosenthebrushholderclampboltsandmovethebrushholderssotheytouchthefiberspacer.

4. Tightentheclampboltsto225-250lbs-ft.torque.Removethespacerandrecheckthebrushholderclearancegaptoensureitis1/16in.

5. Connectthecableleadstothebrushholder terminalsandtightentheterminalbolts.

Inspecting and Testing the Brushholders

Performthefollowingstepswheninspectingandtestingbrushholders.

1. Checkthebrushholderforflashoverdamage,cracksandburnedorpittedareas.

2. Checkthebrushspringstoensuretheymovefreelyanddonotbind.

3. Insertanewbrushinthecarbonwayandmoveitupanddowninthecarbonwaytobesureitmovesfreely.

Replacedamagedbrushholdersiftheyaredamagedorshowsignsofexcessivewear.Formoreinformation,seeReplacing Brushholders.

Replacing the Brushholder Sleeves

Usethisproceduretoreplacebrushholdersleeves.

1. RemovethedamagedTeflonsleevefromthebrushholderstudbyheatingthebrushholderinanovento150°C(302°F)thenpeelingorcuttingthesleevefromthestud.

s WARNING s Wear safety glasses and leather gloves at all times when working with equipment heated to extreme temperatures.

Improper protection can result in serious injury.

2. Thoroughlycleanthesurfaceofthestudto removeanybuild-upofcarbonordirt.

3. HeatanewTeflonsleeveina150°C(302°F)ovenfor15minutes.

4. Immediatelyassemblethehotsleeveonthestud.

28

Reassembling the Brushholders

Usethisproceduretoreassemblethebrushholder.

1. Usingaboltandwasher,attachthebrushholderclamptotheframemount.

2. Positionthestudsofthebrushholderintheclamp,andmovethebrushholderradiallyoutwardasfaraspossible.

3. Tighten,butdonottorque,thebrushholderclampbolt.Formoreinformationontheproperlubricationofassemblyhardware,seeLubricating Bolts.

4. Installallbrushholders.Formoreinformation,see Installing the Brushholders.

5. Connectthebrushholdercables.

The ArmatureInspecting and Testing the Armature

Toavoiddamagetothecore,banding,endturns,shaftfitsandcommutator,handlethearmaturecareful-lyduringinspectionandtesting.Forfurtherprotection:

• Supportthearmatureinasaddletoprotectthe commutatorandthecoilends.

• Coverthecommutatorwithheavypaperuntil youcompletedallworkonthearmature.

Usethisproceduretoinspectandtestthearmature:

1. Bringthearmaturetoroomtemperature,25°C(77°F).

2. Performadielectrictestofthearmatureinsula-tionusinga500or1000VDCmegohmmeter.Youwantareadingofonemegohmorhigher.

Ifyougetavaluelowerthanonemegohmperformthefollowingactionstoincreasetheresistancevalueoftheinsulation:

a. Performadditionalcleaningandbaking operations.

b. Replacethecreepageband.

c. Rewindthearmature.

3. Measureandrecordthearmatureresistance.Forresistancevalues,see General Specifications.

4. Iftherearenogroundedarmaturecoils, performabar-to-barcomparisontesttocheckforopenorshort-circuitedarmaturecoils.

a. PassaregulatedDCcurrentthroughthe armaturecoils.

b. Readthevoltagedropbetweenthe commutatorsegmentswithamillivoltmeter.If thereadingvariesmorethan±5%,youhave adefectiveorshort-circuitedcoil.

5. Ifthearmaturefailsthebar-to-bartest,you mustrewindthearmature.

Replacing the Armature Creepage Band

Werecommendyouusethehotbondprocesswhenreplacingthearmaturecreepageband.ThisprovidessuperioradhesionpropertieswhenattachingtheTeflon®creepagebandontheouterendofthecom-mutator.YoureceiveacopyofthisprocessineachTeflonBandKit(PartNo.76518)[email protected].

Assembling the Armature into the Frame (Models YZE, YZK, ZE-F, ZK-F, ZE, ZK)

UsethisproceduretoassemblethearmatureintotheframeformodelsYZE,YZK,ZE-F,ZK-F,ZE,ZK:

Note: For information on the proper lubrication of assembly hardware, see Lubricating Bolts.

1. Assemblethebrushholders(51)intotheframe.

a. Positionthebrushholderwellbackfromthecommutatortokeepthemclearfromthe commutator.

b. Fastenandinsulatetheconnectionsand installoutgoingcables.

2. Assemblethecommutator-endframehead(45)totheframe.

a. Tightenboltsandwashers(43)uniformly.

29

The A

rmature

b. Torqueboltsto450±50lbs-ft.

3. Usingaheavydutystand,blockandleveltheframeinaverticalposition,commutator-enddown.

4. Assemblealiftingbailontothedrive-endoftheshaft.

5. Wrapheavypaperaroundthecommutatortoprovideextraprotection.

6. Installthebearingpilotonthethreadsofthecommutator-endoftheshaft.

7. Withthebearingpilotandthecommutator-endbearinginnerraceassembledontotheshaft,lowerthearmaturepartwayintotheframe.Usethebearingpilottoaligntheshaftwiththecenterofthebearing.Lowerthearmatureintotheframeuntilthedrive-endframeheadstartsintotheframefit.

8. Insertthedrive-endframeheadboltsandwashers.

a. Removeanyburrsordirtbetweenthefits oftheframeheadandthemagnetframe.

b. Drawdowntheboltsandwashersuniformly topressthearmatureintoplace.Makesure todrawthemdownevenlytoavoidcocking thebearingassemblyanddamagingthe races.

CAUTION: Uneven tightening of bolts could dam-age bearings or related fitted surfaces.

9. Torqueframe-headbolts(43)to450±50lbs-ft.

10. Removethebearingpilot.

11. Removethecommutator-endbearingcap(42).

12. Usingafeelergauge,checktheradialclearance betweentherollersandtheinnerraceonthe commutator-endbearing.Theassembled clearancemustmeasurebetween0.001and 0.003in.

13. Placethemachineinahorizontalposition.

14. Checkthecommutator-endbearingrunout.

a. Withthetipagainsttheouterraceofthe

bearing,clampanindicatortothecommutator-endoftheshaft.

b. Toeliminateend-playanddetermineiftheouterraceistrue,pushthearmature towardthecommutator-end.Iftheouterraceisoutmorethan0.003in.,besurethatthedrive-endframeheadboltsarepulleduptightandthatthereareno burrsordirtbetweenthefitsoftheframeheadandthemagnetframe.

c. Assemblethethrustringontotheendoftheshaft.Positionittightlyagainstthebearinginnerrace.

d. Usingan18-in.spannerwrench,assembletheretainingnutontotheendoftheshaft.

e. Firmlytaptheendofthewrenchwitha10-lb.bronzehammeruntilthenutstopsturning.Ifyouhaveatorquewrench available,torquethenutto500lbs-ft.

f. Locktheretainingnut(48)byassemblingandtighteningtwosetscrews(47)withatorquewrenchsetto38to42lbs.-ft.Ifasuitabletorquewrenchisnotavailable,tightenthesetscrewswithastandardAllenwrenchbyfirmlytappingthe wrenchwitharawhidemalletuntilthescrewsstopturning.Theimpression madebythesesetscrewsintheshaftlockstheretainingnutinplace.

g. Lockthesetscrewsbyprick-punchingthethreadsintwoplaces.

h. Pack2.8oz.ofgreaseintotheouter circumferenceofthebearingcap(42).

i. Placethegasket(44)intopositionontheouterbearingcap(42);assemblethecaptotheframehead(45)withboltsand lockwashers;andtightenboltsto110to120lbs-ft.

15. Checkthedrive-endbearingrunout.

a. Removethedrive-endouterbearingcap (2)andcheckthealignmentoftheouter bearingracebyclampinganindicatorto theshaft.

30

b. Iftheouterracerunsoutmorethan0.004 in.,besuretherearenoburrsordirt betweentheregisterfitsoftheframe headandthemagnetframeandthatthe frameheadboltsarepulleduptight.

16. Usingafeelerguage,checktheradialclearancebetweenthedrive-endbearingrollersandtheinnerrace.Theassembledclearanceofthedrive-endbearingmustbebetween0.0012and0.004in.

a. Withthebearing(6)andcap(10)properly filledwithgrease,andthegaskets(5)in place,assembletheouterbearingcap(2) andtightenthebolts(3)to110to120lbs-ft.

b. Heattheoutersleeve(1)to110°C(230°F) andshrinkitontotheshaftuntilitistight againsttheinnerraceofthebearing.

17. Usingadialindicator,checkthearmatureend-play;end-playshouldmeasure between0.006and0.010in.

Assembling the Armature into the Frame (Models YZB, YZH, ZB-F, ZH-F, ZB, ZH)

UsethisproceduretoassemblethearmatureintotheframeformodelsYZB,YZH,ZB-F,ZH-F,ZB,ZH:

Note: For information on the proper lubrication of assembly hardware, see Lubricating Bolts.

1. Assemblethebrushholders(51)intotheframe.

a. Positionthebrushholderwellbackfromthe commutatortokeepthemclearfromthe commutator.

b. Fastenandinsulatetheconnectionsand installoutgoingcables.

2. Assemblethecommutator-endframehead (45)totheframe.

a. Tightenboltsandwashers(43)uniformly.

b. Torqueboltsto467±27lbs-ft.

3. Usingaheavydutystand,blockandleveltheframeinaverticalposition,commutator-enddown.

4. Assemblealiftingbailontothedrive-endoftheshaft.

5. Wrapheavypaperaroundthecommutatortoprovideextraprotection.

6. Withthecommutator-endbearingandbearinghousingassembledontotheshaft,lowerthearmatureintotheframeuntilthebearinghousingenterstheframehead.Continuetolowerthearmatureintotheframeuntilthedrive-endframeheadstartsintotheframefit.

7. Insertboththedrive-endandcommutator-endframeheadboltsandwashers.

a. Removeanyburrsordirtbetweenthefits oftheframeheadandthemagnetframe.

b. Drawdowntheboltsandwashersuniformly topressthearmatureintoplace.Makesure todrawthemdownevenlytoavoidcocking thebearingassemblyanddamagingthe races.

CAUTION: Uneven tightening of bolts could dam-age bearings or related fitted surfaces.

8. Placethemachineinahorizontalposition,tightenallframeheadbolts(41)andtorqueboltsto467±27lbs-ft.

9. Pack5.25oz.ofgreaseintotheoutercircumfer-enceofbearingcap(42).

a. Placethegasket(44)inpositiononthe bearingcap.

b. Assemblethecaptotheframehead(45) withboltsandlockwashers(41,43).

c. Torquebolts(41)to110to120lbs-ft.

10. Checkthedrive-endbearingrunout.

a. Removethedrive-endouterbearingcap (2)andcheckthealignmentoftheouter bearingrace.

b. Clampanindicatortothedrive-endofthe shaftwiththetipagainsttheouterraceof thebearing.

c. Pushthearmaturetowardthedrive-endto eliminateend-playandrotatethearmature toseeiftheouterraceistrue.Iftheouter racerunsoutmorethan0.004in.,besure therearenoburrsordirtbetweenthe registerfitsoftheframeheadandthe

31

The A

rmature

magnetframeandthattheframehead boltsarepulleduptight.

11. Withafeelerguage,checktheradialclearance betweenthedrive-endbearingrollersandthe innerrace.Theassembledclearanceofthe drive-endbearingmustbebetween0.0012and 0.004in.

a. Withthebearing(6)andcap(10)properly filledwithgrease,andthegaskets(5)in place,assembletheouterbearingcap(2) andtightenbolts(3)to110to120lbs-ft.

b. Heattheoutersleeve(1)to110°C(230°F)andshrinkitontotheshaftuntilitistightagainsttheinnerraceofthebearing.

12. Usingadialindicator,checkthearmature end-play;end-playshouldmeasurebetween 0.006and0.010in.

Removing the Armature Locking Arrangement

Usethisproceduretoremovethearmaturelockingarrangement:

1. Removethetwoshippingboltsfromthebearingcap.Theseboltshaveyellowheadsandarelongerthantheotherbolts(seeFigure1).

2. Installthetworegularbolts.Theregularboltsareinabagattachedtooneoftheshippingbolts.

3. Torquetheregularboltsto115lbs-ft.

Note: Put the shipping bolts back in the bag and save them in case you need to lock the armature at a later date.

Locking the Armature for Shipment

Locatethebagwhereyouhavetheshippingboltsandusethisproceduretolockthearmatureforshipping:

1. Removetwodiametricallyoppositeboltsinthecommutator-endbearingcap.

2. Installtheshippingbolts(thelongerboltswiththeheadspaintedyellow,asshowninFigure1)withjamnutsapplied.

3. Torquetheboltsto30lbs-ft.andtightenthejamnuts.

Caution: Do not rotate the armature when the locking bolts are in place. This can damage the bearings and the commutator.

4. Placethetworegularboltsinthebagandattachthebagtooneoftheshippingbolts.

Testing the Armature After Repair

Onceyouhavecompletedallworkonthearmature,usethisproceduretotestthearmaturebeforebringingitbackintoservice:

1. Applyahighpotentialtestvoltagebetweenthecommutator(withallsegmentsshorted)andtheshaftbasedonthefollowingcriteria:

• Usedarmature-2000volts,60Hzforoneminute

• Rewoundarmature-3500volts,60Hzforoneminute



Note: Measure leakage current to ground during test 3-85.0 milliamps.

2. Conductaresistancemeasurement.Forthearmatureresistancevalue,seeGeneral Specifications.

Yellow Armature Locking BoltsFigure1

32

Armature Varnish Treatment

Afteryouhaveeithercleanedandrepairedorre-woundthearmature,itmustbevacuumpressureimpregnated(VPI).

Balancing the Armature

Dynamicallybalancethearmaturewithin10grams(0.35oz.)onthedrive-endand12grams(0.42oz.)onthecommutator-endbyaddingweightsonthecommu-tatorcapandthearmaturehead.

InspectionsInspecting the Insulation

Inspecttheinsulationofarmaturecoilsforcracks,physicaldamage,burnsanddeterioration.Replaceorrepairtheinsulationasrequired.

• Glass Band,Commutator-endInspecttheglass bandsforsplittingorfraying;ensurethereareno looseconnections.

• Wire Band,Drive-endInspectthewirebandfor physicaldamage,loosetieclipsorbrokenwire.

• Creepage Band Inspectthesurfaceofthe Teflon®creepagebandforpossibleflashover damage.Tapthebandlightlyandcheckfor movement.Youmustreplacethebandifitisloose orhasdeepburns.Formoreinformation,see Replacing the Armature Creepage Band.

Inspecting the Commutator

Checkthecommutatorforthefollowingconditions:

• Overallappearancetoensurethe commutatorisfreeoftreading,pitting, grooving,burns,flatspots,highbarsand copperdrag.

• Concentricitytoensurethatthecommutatorisnotout-of-round.Forconcentricitylimits, see General Specifications.

• Propersizetoensurethediameterofthe commutatoriswithintheallowablesize range.Fortheminimumpermissible commutatordiameterdimension,see General Specifications.

• Properalignmenttoensuretherearenohighbars (thecommutatorisnotloose).

Whenrequired,resurfacethecommutator.Formoreinformation,seeResurfacing the Commutator.

Note: If after resurfacing, the brush surface diameter will be less than the minimum permissible diameter, you must replace the commutator.

Inspecting the Armature Shaft Bearing Fits

Comparethearmatureshaftbearingfitdimensionstoensuretheyarewithinthefollowingtolerances:

+ 0.0000 - 0.0008

5.9077 BEARING FIT PE

+ 0.0000 - 0.0008

5.1203 DIA. BRG. FIT OPE

(Double Shaft)

+ 0.0000 - 0.0007

3.9389 DIAM. (BRG. FIT) OPE

Ifthedimensionsarenotwithinthetolerancesyoumustrepairorreplacethearmatureshaft.

Inspecting the Creepage Band

Inspectthecreepagebandforthefollowingconditions:

• Nogapsshouldbevisibleatthejointorbetween theedgeoftheTeflonbandandthecopperbars.

• Thebandsurfaceshouldbesmooth,freeof varnishandbondedtotheunderlaymaterial.

• NobubblesshouldappearundertheTeflon.

• Thebandshouldhavenobuckling.

• Thesurfaceshouldbefreeofdamageandnot havescratchesorcuts.

Replacethecreepagebandwhenrequired.

33

Resurfacing the Commutator Beforeturningorgrindingthecommutator,youmustensurethereissufficientstocksothecommutatorwillnotbeturnedorgroundbelowtheminimumpermissi-blediameter.SeeGeneral Specificationsfortheminimumpermissiblecommutatordiameterdimension.Formoreinformation,seePreparing the Commutator for Resurfacing.


s WARNING s Resurfacing operations can raise dust and flying parti-

cles. Wear safety glasses and a respirator for protection from dust and flying particles during resurfacing opera-tions. Improper protection can result in serious injury.

Grinding

Usethefollowingproceduretogrindthecommutator:

1. Truetheshaftcenterswithrespecttothebearingfitsbyscraping.

2. Placethearmatureeitherinalatheequippedwithagrindingattachmentorinagrindingmachine.Checktheconcentricityofthebearingfits.TheTIRshouldnotexceed0.001in.

3. Coverthearmaturewindingstokeepitclearfromdebris.

4. Grindthecommutatorandcheckthecommuta-torrunoutwithadialindicator.Themaximumcommutatorrunoutis0.001in.

5. Performtherequiredundercutting,rakingandpolishing.

Turning

Ifthesurfaceofthecommutatorisbadlyworn,burnedorscarred,itrequiresturning.Usethefollowingproceduretoturnthecommutatorinalathe:

1. Truetheshaftcenterswithrespecttothebearingfitsbyscraping.

2. Placethearmatureinalatheandchecktheconcentricityofthebearingfits.TheTIRshouldnotexceed0.001in.

3. Coverthearmaturewindingstokeepitclearfromdebris.

4. Setthecuttingtoolforturningcopper,andsetlathespeedtogivethecommutatorasurfacespeedof300feetperminute.

5. Makeclean,smoothcutstoremovejustenoughcoppertorenewthecommutatorsurface.Donotallowthecuttingtooltochatter.Forthedimen-sionsofthedustgroove,see General Specifications.

6. Afteryouhavecompletedtheturning,checkthecommutatorrunoutwithadialindicator.Themaximumcommutatorrunoutis0.001in.

7. Performtherequiredundercutting,rakingandpolishing.

Undercutting

Youcanuseahacksawbladetoundercutthecom-mutator.Werecommendyoukeepthebladesharp;asthebladedullsitcanproducesmallcracksinthemicawheredirtormoisturecanbuildupandbreakdowntheinsulationbetweenthecommutatorsegments.Withpractice,youcanuseahand-heldpowerundercutter.

Whenusingapowerundercutter,followthetoolmanufacturer’sinstructionsanduseslotguidesanddepthgaugestoensureaccurate,uniformcuts.Werecommendyoutakeafewpracticepassesoverascrapcommutatortogetabetterunderstandingonhowthetoolreacts.Youmustkeepthepowerunder-cutterfromjumpingoutoftheslotandacrossthecommutatorsurface;thehigh-speedoperationofthebladewillquicklygougethecommutator.

Afteryouhaveresurfacedthecommutator,usethisproceduretoundercutthecommutator:

Resurfacing the C

omm

utator

34

1. Undercutthemicabetweenthebarstoadepthof0.047in.Youshouldperformtheundercuttingwithasharp-edgedtoolhavingacuttingwidthof0.063in.

2. Blowloosematerialoffthecommutatorwithdry,compressedair.


debris and flying particles. Wear safety glasses and other personal protective equipment when using compressed

air for cleaning purposes. Flying debris and particles may also present a hazard to personnel in the immediate area.


Raking

Resurfacingtypicallyleavesparticlesandsliversofcoppereitherhangingonthebaredgesorlodgedintheundercutslots.Theseparticlescanbridgethesidemicaandcauseaflashover.Toensuresafeoperation,youmustremoveparticlesbeforeyoucanplacethemotorbackinservice.

Usethisproceduretorakethecommutator:

1. Usingastiff-bristlenylonbrush,brushoutanyloosedirtorcoppersliversattachedtothetrailingedgeofthebars.Youcanalsouseanewpaintbrushorstencilbrushwiththebristlescutshorttoaddstiffness.

2. Ifstoningandundercuttingpulledalargeamountofcopperfromtheedgesofthebars,useeitherarakingtoolorapieceoffiberboardapproxi-mately0.045in.thicktoremovethecopperfinsandraggededges.Whenusingarakingtool,usethetooltorakethebaredgeswiththepointinsertedintheslotsothatsidesofthetoolrakethetrailingedgeofthebar.Ifthetoolisgroundwithflatsidesandusedwithmoderatepressure,itwillremoveraggedcopperfinsandbreakthesharpedgesofthebars.

3. Aftertheslotshavebeenraked,usefinesandpa-pertosandthecommutatortoremoveadditionalsmallpiecesofcopperattheedgesoftheslots.

4. Thoroughlycleanthearmaturecoreandcommutatorwithdry,compressedairtoremovecopperanddust.





Polishing

Ifthecommutatorisdiscoloredorsmudged,usethisproceduretopolishthecommutator:

1. Usingcanvas,crocuscloth,fine(4/0)sandpaperor400ATriemitepaper,polishthecommutator.Ifyouareusingabrasivepaper,youshouldmountitonawoodenblockcurvedtofitthesurfaceofthecommutator.

CAUTION: Never use an emery cloth on a com-mutator. The abrasive particles on emery cloth scratch the commutator surface and lodge in the grooves between commutator segments. This can create conditions that can eventual lead to flash-over which could seriously damage the machine.

2. Blowloosematerialoffthecommutatorwithdry,compressedair.





3. Checkthecommutatorconcentricitywithadialindicator.Fortherun-outlimits,seeGeneral Specifications.

4. Coverthecommutatorwithheavypaperorfelttoprotectitfromdamageuntilyouarereadytobringitbackintoservice.

35

The Motor FrameInspecting and Testing the Motor FrameUsethefollowingproceduretoinspectandtestthemotorframe:

1. Inspectthefollowingelementsofthemotorframe:

a. Checktheconnectionstrapinsulationand theinsulationonthecoilsfordamage,signs ofburning,cracksordiscoloration.

b. Checktheleadcablesfordamage, overheatingandsignsofdeterioration.

2. Replaceanymotorframepartsthatfailtheinspection.Formoreinformation,see Replacing the Motor Frame Field Coil.

3. Performthefollowingtests:

a. Conducta1,000voltmegohmmetertest onthecoilsandlookforareadingof20 megohmsormore.

b. Measureandrecordcommutatingand exciting-coilresistance.RefertoTable1to determinethecorrectconnectiondiagramfor themachinebeingrepaired.

c. High-potentialtestthefieldcoilstogroundby applyingahigh-potentialtestof3,400VDC, 60Hzforoneminute.



4. Replaceanymotorframepartsthatfailtesting.Formoreinformation,seeReplacing the Motor Frame Field Coil.

Replacing the Motor Frame Field CoilYouperformthefollowingstepswhenyoureplacethemotorframefieldcoil:

• RemovingtheCoil

• InstallingtheCoil

ContactJOLIETEquipmentCorporationtodeterminethecorrectcoiledframeassemblydrawingforthemachinebeingrepaired.

Removing the Coil

1. Removeterminalinsulationanddisconnectthecoilleads.Useeitheragastorchorbrazingtongstoseparatethebrazedconnections.Whenyouareusingbrazingtongs,uselowvoltageandhighACcurrenttoheatthecoilconnections.

s WARNING s Brazing requires extremely high temperatures. Wear safety glasses and leather gloves at all times during brazing operations. Improper protection can result in

serious injury.

2. Packabsorbentbotharoundtheinsulationnearthecoilconnectionandovertheadjacentcoils.

Note: If you are using a gas torch, protect the coil insulation from the heat using a non-flammable heat absorbent, such as interwoven glass cloth.

3. Ensureallexposedinsulationiscoveredwithathicklayerofabsorbent,thenheatandseparatethecoilconnections.

4. Softenthevarnishinordertoremovethepoleboltsbyheatingthecoiledframeinanovenat150°C(302°F)forfourhours.

5. Removethepoleboltsandthecoil-poleassem-blyfromthemagnetframe.

6. Markanyshimsforreassemblywiththecorre-spondingpolewhenthecoil(s)isinstalledintheframe.

Inspecting/Testing the Frame

36

Installing the Coil

Youmustinstallanyexcitingcoilsandbrazetheirconnectionsbeforeyoucaninstallcommutatingcoils.Formoreinformation,seeBrazing the Coil Terminals.

Usethefollowingproceduretoinstallnewcoil-poleassemblies:

1. Cleanboththepolecontactsurfaceonthe frameandthepolepiecemountingsurface.

2. InstallthenewpoleandcoilintheframewithNomexInsulatorandanyshimsthatwereonthedamagedcoil.Replaceoldwashersundertheboltheadswithnewwashers.

3. Lubricatetheboltheads,threadsandwashersanddrawthepoleboltsmoderatelytight.

4. Brazethecoilconnections.Formoreinforma-tion,seeBrazing the Coil Terminals.

Brazing the Coil Terminals Youmustbrazeallcoilconnectionswithsilversolder,JECAG101.Usetwopiecesofsolder(0.010x1in.x1in.)betweentheterminalsurfaces.Youcanbrazethecoilterminalsusingeitherthemachinebrazingmethodorthegastorchmethod.

Using the Machine Brazing Method

Usethefollowingproceduretobrazethecoiltermi-nalsusingmachinebrazing:

1. Setthebrazingcurrentto10,800amperesat1.6volts.

2. Insertsilver-solderbrazingstripsbetweenconnections.

3. Clampthebrazingtongsontheconnectionandbrazethejoint.Ifnecessary,addadditionalsoldertofillthejointandformalevelsurface.

4. Brazeallexciting-coilconnections.Whencomplete,youcaninstallthecommutatingcoils.

Using the Gas Torch Brazing Method

Usethefollowingproceduretobrazethecoiltermi-nalsusingthegastorchbrazingmethod:

1. Packthecoilinsulationwithnon-flammableheatabsorbentmaterialsuchasinterwovenglasscloth.

2. InsertthebrazingstripsanduseaC-clamporvise-gripplierstoclamptheconnectionsurfacestightlytogether.

3. Useatorchtipwitha0.1in.orificeandadjustthetorchtoobtainaslightlyreducedflame.

4. Meltthebrazingstrips;astheymelt,addmoresoldertofillthejointandformalevelsurface.

5. Removetheheatabsorbentpackingfromtheinsulation.Usedry,compressedairandblowouttheinsideoftheframe.





6. Torquethepolebolts.Formoreinformation,see Standard Torque Values.

7. Checkthepolarityofthefieldpoles;energizethefieldcircuitwithabatteryandcheckthepolepolaritywithacompass.

8. InsulatetheconnectionswithsiliconeputtyandwraptheconnectionswithMylarfilm.

9. Usingglasstape,wraptheconnectionsothattheglasstapeextends1/2inchbeyondthebareareaoftheconnection.

10. Installandconnectanycablesthatyou previouslyremoved.

11. Flooddipthecoiledframe.Youcanflood-dipthecoiledframeonlyafteryouhaveinsulatedtheconnectionsandinstalledanycablesyouhadpreviouslyremoved.Formoreinformation,seeFlood Dipping the Coiled Frame.

Bra

zing

the

Coi

l Ter

min

als

37

Flood Dipping the Coiled Frame

Youinsulatethecoiledframebyflooddippingonlyafteryouhaverepairedorreplacedthefieldcoilsandhavecompletedallelectricaltests.

Youusevarnishforflooddipping.Forbestcoverage,agitatethevarnishfor15minutesbeforedippingtheframe.

Usethefollowingproceduretoflooddipthecoiledframe:

1. Checkthatyouhavemadeallcoilconnections;thattheconnectionsareproperlyinsulated,andthatallcablesandtiesforcablesandconnectionstrapsareinplace.

2. Tiecableendsabovethevarnishlevel.

3. Coatallmachine-fitsurfaceswitheitherblackvarnishorstrippingcompoundandplugboltholeswithdummybolts.

4. Heatthecoiledframeto40-80°C(104-176°F)anddiptheframedrive-enddown(withallcoilconnectionscovered)foratleast15seconds.

5. Drainandremovetheframefromthevarnishandallowtheframetodrainforatleast5min-utesinaverticalposition,drive-enddown.

6. Pre-heattheovento150°C(302°F)andbaketheframebasedonthevarnishmanufacturer’sspecifications.

7. Cleanthevarnishfromallmachinedsurfacesandunplugthetappedholes.

Testing the Coiled FrameTesting after Repair (without Armature)

Usethefollowingproceduretotestthecoiledframe(withoutarmature)afterrepair:

1. Pass24.0amperes(60Hzcurrent)throughtheexciting(series)fieldandreadthevoltagedrop.Itshouldbewithinthefollowingrange:

• MinimumVolts13.1

• MaximumVolts15.6

2. Pass24.0amperes(60Hzcurrent)throughthecommutating(CP)fieldandreadthevoltagedrop.

Fornon-magneticretainersitshouldbeinthefollowingrange:

• MinimumVolts7.3

• MaximumVolts8.5

Formagneticretainersitshouldbeinthefollow-ingrange:

• MinimumVolts10.7

• MaximumVolts12.4

Testing After Repair

Usethefollowingproceduretotestthecoiledframeafterrepair:

1. Applyahighpotentialtestvoltageaccordingtothefollowingcriteria:

• Usedcoils–2000volts,60Hzforone minute

• Newcoils–3500volts,60Hzforone minute

Duringthistest,measureleakagecurrenttoground;themaximumallowableleakageis5.0milliamps.



2. Conductaresistancemeasurement.Fortheresistanceoftheexcitingandcommutatingfields,seeGeneral Specifications.

38

The Connection BoxesChanging the Position of the Connection Box

Youcanchangetheconnectionboxonamachinefromonesidetotheother.

Usethefollowingproceduretochangeaconnectionboxforseriesmotorsfromtherightsideofthemachinetotheleftside.TherearedifferencesinworkingwiththeF1andF2cableswhenchangingthepositionoftheconnectionboxesonshuntmotors.Formoreinformation,seeDifferences for Shunt Motors.

Note: To change the connection box from the left side of the machine to the right side, reverse the specific side-oriented steps.

1. Disconnectallaccessoriesfromtheconnectionbox.

2. Removetheconnectionboxcovers.

3. DisconnecttheF1,F2,A1andA2leadsfromtheconnectionbox.

4. Loosenthestrainreliefconnectorsatthebottomoftheboxandremoveallcablesandconduitfromthebottomofthebox.

5. Disconnecttheblowerandheaterleadsfromtheterminalboard,theblowerandheaterconduitandfittingsfromtheconnectionbox,andremovetheleads.

6. Disconnectthepressurizingassemblyandfittingfromtheconnectionbox.

7. Disconnectthepressuresensingtubefromtherearoftheconnectionbox.

8. Removethemountingboltsandlifttheconnec-tionboxoffoftherightsideofthemotor.

9. Removethepressuresensingtubeandfitting,theheaterconduitandfitting,andthepressuriz-ingconduitandfittingfromtheright sideofthecommutatorchamber.

10. Removethepipeplugsfromtheleftsideofthe commutatorchamberandinstallthepipeplugs inmatchingholesontherightside.

11. Removetheheaterleadsandheaterfromthe commutatorchamber.

12. ChangetheF1andF2leadsfromtherightside totheleftsideusingthefollowingsteps:

a. Removethelowersplashguardsfromthedrive-endofthemotor.

b. RemovetheinsulationfromtheF1andF2connectionsinsideofthemagnet framethroughtheairoutletholes.

c. RemovetheboltsfromtheconnectionsandremovetheF1andF2externalleadsfromtheelbowinthemagnetframe.

d. Removetheelbow.

e. Insulatethebareterminalsleftinthe magnetframeand,ifnecessary,tie downtheleads.Formoreinformation,seeInsulating the Terminal Connections.

f. RemovethepipeplugfromtheleftsideofframeandinstallintheholevacatedbytheelbowandtheF1andF2leads.

g. RemovetheinsulationfromtheF terminalsinsideofthemagnetframeontheleftsidethroughtheairoutlethole.

h. InstalltheelbowandtheF1andF2leadsintheholeontheleftsideofthemagnetframe.

i. ConnecttheF1andF2leadstothecorrectbareterminalsandre-insulatetheterminalconnections.Formoreinformation,seeInsulating the Terminal Connections.

j. Replacethelowersplashguards.

13. ChangetheA1andA2leadsfromtheright sidetotheleftsideusingthefollowingsteps:

a. Removethecommutatorinspection covers.

b. Removetheblowermountingbolts.

The

Con

nect

ion

Box

es

39

The C

onnection Boxes

c. Removetheblowerfromtheairinlethole.

d. DisconnecttheA1leadfromtheconnec-tionbusbarthroughtheblowerinlethole.

e. Removetheleadfromthemagnetframe.

f. RemovetheinsulationfromtheA2 connectionanddisconnecttheA2leadfromtheconnectionbusbar.

g. Removetheleadfromthemagnetframe.

h. Removethebushings.

i. RemovethepipeplugsandcapsfromtheholesintheleftsideoftheframeandinstallthemintheholesvacatedbytheA1andA2cablesandbushingsintherightsideoftheframe.

j. Installbushingsintheleftsideholes.

k. ThreadtheA2leadthroughthecommuta-torchamber,fromtherightside,undertheconnectionstrap,andoutthroughthelowerbushingsontheleftside.

l. ConnecttheA2leadtotheconnectionbusbarusingtheholesadjacenttothecommutatingcoilconnection.

m. Insulatetheentireconnection.Formoreinformation,seeInsulating the Terminal Connections.

n. Tietheleadtotheconnectionstrap.

o. InstalltheA1leadthroughtheupper bushingontheleftsideandboltittotheconnectionbusbar.

p. Re-aligntheblowerwiththeairinletholeandboltitinplace.

Insulating the Terminal Connections

Usethefollowingproceduretoinsulatetheterminalconnections:

1. FillallcavitiesandcoverallboltheadswithDuctSeal.

2. Insulatetheentireterminalassemblywithvarnishedclothtape.

3. Tapetheterminalassemblewithglasstape.

4. Half-lapthetapings.

5. Afteryoucompletethesecondtaping,coattheentireassemblywithairdryvarnishorepoxy.

Assembling the Connection Box

Usethefollowingproceduretoassembletheconnec-tionboxandaccessoriestotheoppositesideofmotor:

1. Installthepressuresensingfittingandtheheaterconduitfittingintheappropriateholesontheleftsideofthecommutatorchamber.

2. Installtheheater.

a. Threadtheleadsthroughthecommutator chamberandouttheheaterconduitfittingon theleftsideofthechamber.

b. Tietheleadsinsidethechamberwhere necessary.

3. Installtheconnectionboxontheleftsideofthe motor.

4. InstalltheA1-A2cablesupportonthecommuta-tor-endmountingblock.

5. Connectthepressuresensingtubetothecommutatorchamberfittingandtotherearoftheconnectionbox.

6. Disconnecttheauxiliaryswitchleadsfromtheterminalboard.Interchangetheauxiliaryswitchwiththecoverattheoppositesideoftheconnec-tionboxandreconnecttheauxiliaryswitchleads.

40

7. Installtheheaterconduitandfittingstotheconnectionboxandconnecttheleadstotheterminalboard.

8. Installthepressurizingassemblybetweenthecommutatorchamberandtheconnectionbox.

9. InstalltheA1andA2leadsthroughthestrainreliefconnectorstotheconnectionsinsidetheconnectionbox.

10. InstallboththeF1andF2leadsandthe conduitthroughthestrainreliefconnectorsand connecttheF1andF2leadstotheterminal board.Onceinstalled,tightenallstrainrelief connectors.

11. Installtheblowerconduit,fittingandcablesto theconnectionbox;thencompletethe connectiontotheterminalboard.

12. Testtheblowertoensureithasthecorrect rotation.

13. Plugallvacantholesintheconnectionbox withthesuppliedplugbuttons.Lockthemin placebybendingfourprongsoverat90 degreesapart.

14. Installthetopandfrontcoversontheconnection box.

15. Immediatelydocumentthemachine’shistoryof changestokeeptheinformationup-to-date.

16. Ensurethatyouplugallholesfromwhichcables havebeenremoved.

Differences for Shunt Motors

Therearedifferenceswhenchangingthepositionoftheconnectionboxesonshuntmotors.Whenchangingthepositionoftheconnectionboxonshuntmotors,youmust:

• Removetheinsulationfromthecableconnections oftheF1andF2cablesontherightsideandthe busbarconnectionontheleftside.

• Reconnectthecablesasshownintheappropriate connectiondiagram.

• Re-insulatetheconnections.Formoreinformation, seeInsulating the Terminal Connections.

• Interchangethecapsandplugswiththebushings.

41

The CommutatorResurface Based on Condition Youcanresurfacethecommutatorbysanding,stoningorgrinding;choosethemethodbasedontheconditionofthecommutator.Youmustalsohaveanoutsidepoweravailabletooperatethemotorwhenresurfacingthecommutator.Formoreinformation,seeResurfacing the Commutator.


Safety RequirementsResurfacingthecommutatorcanbedangerous.Toensureyouresurfacethecommutatorsafely,werecommendyouadheretothefollowingsafetyprecautions:

• Toprepareforpossibleemergencies,stationa secondoperatorattheauxiliarypower(welder) controlreadytoshutoffthepower.

• Toavoidelectricalshock,theoperatorshould wearrubberinsulatedgloves,nottouchanypart ofthemachineinteriororcablesduringgrinding operations,standonaninsulatedplatformwhen resurfacingorblowingoutthecommutator,and alwaysuseanelectricalnon-conductinghosetip whencleaningwithair.

• Tostaysafefromdustandflyingparticles,the operatorperforminggrindingandcleaningwith compressedairshouldwearsafetyglassesand arespiratorforprotectionfromdustandflying particles.Improperprotectioncanresultin seriousinjury.

• Toavoidpossibleseriousinjuryordeath,keep clearofanenergizedmotorduringthecleaning processasthearmaturecommutatorandbrush rigginghaveahighelectricalcharge.

CAUTION: Never use an emery cloth on a com-mutator. The abrasive particles on emery cloth scratch the commutator surface and lodge in the grooves between commutator segments. This can create conditions that can eventual lead to flash-over which could seriously damage the machine.

Preparing the Commutator for ResurfacingPreparing for Resurfacing for Series Motors

Usethisproceduretopreparetoresurfacecommuta-torsforseriesmotors:

1. Breakthecoupling(ifapplicable)sothatyoucanoperatethemachinefromanoutsideDCpowersourcesuchasaDCweldingset.

2. Liftallthebrushesexcepttwoofoppositepolaritythathaveadjacentbrushholdersthatarerequiredtooperatethemotor.

3. Disconnectthemotorcables.

4. ConnectthemachinetotheoutsidecontrolledDCpowersource,suchasa3-5KW,100VDCweldingset,thatiscapableofdrivingthemotorataspeedof900-1000RPM.

5. RefertoFigure2foradiagramofconnectionsrequiredtoruntheseriesmachinefromaweldingsetthatthearmaturerotatescounter-clock-wise(asviewedfromthecommutator-end):

Figure 2

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42

Preparing for Resurfacing for Shunt Motors

Usethisproceduretopreparetoresurfacecommuta-torsforshuntmotors:

1. Breakthecoupling(ifapplicable)sothatyoucanoperatethemachinefromanoutsideDCpowersourcesuchasaDCweldingset.

2. Liftallthebrushesexcepttwoofoppositepolaritythathaveadjacentbrushholdersthatarerequiredtooperatethemotor.

3. Disconnectthemotorcables.

4. ConnectthemachinetotheoutsidecontrolledDCpowersource.RefertoFigure3foradia-gramofconnections.

Figure 3

Sanding the CommutatorIfthecommutatorisdirty,blackenedorslightlyrough,resurfaceitbysandingitwith00(orfiner)sandpaper.Usethefollowingproceduretosandthecommutator:

1. Attachthefinesandpapertoawoodenblockwithacurvedshapetofitthecommutator.

2. Applypowerasfollows:

a. Increasethefieldsupply(0-50VDC)to32.0 voltsat25amps.

b. Increasethearmaturesupply(0-150VDC)to 150volts.

c. Slowlydecreasethefieldsupplytobringthe speedupto1000RPM.

3. Runthemachineatapproximately1000RPM.

4. Cleanthecommutatorbyholdingtheblockagainstthesurfacewithalight,evenpressureandmovingtheblocklongitudinallybackandforthacrossthefaceofcommutator.

5. Whencomplete,shutdownbyincreasingthefieldsupplytomaximum,andthenturningoffthearmaturesupply.Afteryoushutoffthearmaturesupply,shutdownthefieldsupply.

6. Cleanthemachineusingclean,drycompressedair,toremovedustandsand.





Hand Stoning the CommutatorIfthecommutatorsurfaceismildlygrooved,threadedorburned,withonlyasmallamountofcoppertoberemoved,resurfaceitusingafine-gradehandstone.

Note: Hand stoning will not correct an out-of-round com-mutator. You must fixture grinding to correct an out-of-round commutator. For more information, see Fixture Grinding.

Usethefollowingproceduretohandstonethecommutator:

1. Grindthefine-gradestonetoacurvedshapetofitthecommutator.Thestonemustbewideenoughtobridgeflatspotsonthecommutatorotherwiseitwillrideinandoutoftheflatspotsandnotcorrectthem.

2. Removeonebrushholdertoprovideaccesstothecommutator.

3. Runthemotoratapproximately1000RPM.

4. Cleanthecommutatorbyholdingthestoneagainstthesurfacewithafirm,evenpressureandmovingthestonelongitudinallybackandforthacrossthefaceofcommutator.

5. Cleanthemachineusingclean,drycompressedair,toremovedustandsand.

43





Fixture GrindingIfthecommutatorisgrooved,threadedorout-of-round,resurfaceitusingfixturegrinding.Forthegrindernomenclatureandcommutatorgrinderpartnumber,seeSpecial Tools and Equipment.

Beforegrindingthecommutator,youmustensurethereissufficientstocksothecommutatorwillnotbegroundbelowtheminimumpermissiblediameter.SeeGeneral Specificationsfortheminimumpermissiblecommutatordiameterdimension.

Note: If after resurfacing, the brush surface diameter will be less than the minimum permissible diameter, you must

replace the commutator.

Installing the GrinderMakesurethatthegrinderisreasonablyclean.Additionally,makesurethatthetraverseslidesdonothaveaccumulateddirtandcopperchips;otherwise,thecarriagemaybindduringthegrindingoperation.Cleanthegrinderandtraverseslidesifrequiredbeforeinstallingthegrinder.

Usethefollowingproceduretoinstallthegrinder:

1. Removetheinspectioncoversfromthemachine.

2. Removethemostaccessiblebrushholder,andclampthegrindermountingbrackettotheframe.

3. Removethebrushesfromonebrushholderadjacenttogrinderinacounter-clockwisedirection.

4. Installexistingbrushesintheremaining brushholders.

5. Boltthegrindertothemountingbracket.

Grinding the Commutator Installthestonesinthegrindersotheentiresurfaceofthecommutatorcanberesurfacedwhenthestonestraversethecarriagefromside-to-side.

Recommendation: We recommend that you use finish-grade resurfacing stones for most applications. You can use me-dium grade stones but only either for rough grinding a deeply grooved or threaded commutator, or for grinding a commu-tator with deep flat spots. When you rough grind, you must follow up with finish-grade stones for the final grinding.

Forbestperformance,collectthecopperchipsandabrasivedustastheyareproducedbythegrindingoperation.Forexample,useavacuumcleaningdevicewithasuctionwandsetjustbehindthetrailingedgeofthestones.

Ifyouareusingnewstones,youshouldcontourthemonaCarborundumwheeltoapproximatethecurvatureofthecommutator.

Usethefollowingproceduretogrindthecommutator:

1. Alignthegrindersothattheclearancebetweenthecommutatorsurfaceandthegrindingstoneisapproximately0.030in.

a. Traversethecarriagetooneendofthe commutatorandchecktheclearance betweenthecommutatorsurfaceandone stonewithafeelergaugeorafiberstrip.

b. Traversethecarriagetotheotherendof thecommutatorandchecktheclearance underthesamestone.

c. Ensuretheclearanceisthesameatboth ends.Ifclearanceisnotequalatbothends, adjusttheclearanceusingthesetscrewsin themountingbracket.

2. Movethestonesawayfromthecommutatorusingthefeedcontrol.

3. Startthemachine.

4. Applypowertothemachineandgraduallyincreasethespeedto900-1000RPM.

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5. Begingrinding.

a. Radiallyfeedthestoneslightlyagainst thecommutator.

b. Slowlymovethecarriagebackandforth longitudinallyacrossthesurface.

c. Makesurethecuttingactionoccursatthe trailingedgeofthestones.

d. Makelightcutsandavoidchatter;heavy cutscauseexcessivecopperdrag.

e. Whenthecuttingactionofthestonestops, feedthestonelightlyagainstthecommutator andcontinuegrinding.

6. Continuegrindingthecommutator.

• Donotgrindthecommutatordeeperthanthemicaundercut.

• Donotgrindthecommutatortoadiameterthatissmallerthantheminimumpermissiblediameter.Formoreinformation,seeGeneral Specifications.

• Donotremoveanymorecopperthannecessary.

7. Asyoubegintohaveauniformlysmoothsurfacelightenthecuttingpressureonthestones.Ifyouareusingmediumgradestones,stopthemotor,changetofinish-gradestonesandrepeattheprocedurestartingatStep1.

8. Afterthefinalcut,traversethestonesbackandforthwithoutchangingthefeeduntilallcuttingactionscease.

9. Removepowerfromthemachine.

10. Checkthecommutatorrunoutwithadial indicatortocheckthecommutatorfor concentricity.Formoreinformation,see General Specifications.Ifnecessary,continue grindingtomeetconcentricitylimits.

11. Whenwithinconcentricitylimits,removethe grinder.

12. Rakethecommutatorslotstoremoveprojecting micafinsorcopperwhiskers.Formoreinforma- tion,seeRaking the Commutator.

13. Polishthecommutator.

a. Youpolishthecommutatorusing00 sandpaper,crocusclothor400ATriemitepaper.

b. Mounttheabrasivesheetonawoodenblockcurvedtofitthesurfaceofthe commutator.

c. Startthemachineandrunitagainat 1000RPM.

d. Holdtheblockagainstthesurfacewithalight,evenpressureandmovetheblocklongitudinallybackandforthacrossthefaceofcommutator.

14. Blowthedustfromthecommutatorandthe interiorofthemotorusingdry,compressedair. Holdtheairnozzleonetotwoinchesfromthe surfaceofthecommutatorandsweepnozzle longitudinallytodislodgecopperchipsand micadust.

15. Aircurethecommutator.Formoreinformation, seeAir Curing the Commutator.

45

Air Curing the CommutatorYouaircurethecommutatoronceyouhavecomplet-edanyrequiredsanding,stoningorgrindingandhaveblownthemachineclean.

Usethisproceduretoaircurethecommutator:

1. Rotatethearmatureslowlyusingthesameoutsidepowersourceyouusedforsanding,stoningorgrinding.

2. Witharubberair-hosewiththenozzleremoved,sweepthecommutatorsurfacewith70PSIairpressure.

3. Increasethemachinespeedtoapproximately900RPMandblowaironthecommutatoruntilthesparkingstops.

4. Increasethemachinespeeduntilyoureachfullspeed,butdonotexceed1000RPM,andcontinuetoblowaironthecommutatoruntilallsparkingstops.

5. Stopthemachine.

6. Disconnecttheoutsidepowersource.Makeallnecessarymechanicalandelectricalconnec-tionsrequiredtorestorethemachinetoservice.

7. Wipeoffthebrushholders,creepagebandandaccessiblesurfacesinthecommutatorchamberusingacleancloth.

8. Installthebrushholderthatyoupreviouslyremovedfromthecommutator.Formore information,see Installing the Brushholder.

9. Installthebrushes.Formoreinformation,seeInstalling the Brushes.

10. Vacuumtheinteriorofcommutatorchamber.

11. Bringthecommutatorbackintoservice.

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The Bearings Inspecting the BearingsYoushouldcleanthebearingsbeforestartingyourinspection.Formoreinformation,seeCleaning.Youshouldalsonotinterchangebearingpartsfromadifferentmanufactureormixnewandusedbearingparts.

Usethisproceduretoinspectthebearings:

1. Inspectbearingsforthefollowingwearconditions:

• Brokenorcrackedraces

• Brokenorcrackedrollersandballs

• Broken,crackedordistortedretainers

• Scored,pitted,scratchedorchippedraces

• Excessivewearonrollersandballs

2. Inspectthebearingsforsmearingcausedbyinadequatelubrication

3. Inspectthebearingsforcorrosionpitting(usuallyattherollerspacing)causedbymoistureorothercorrosiveagents.

4. ReplacethebearingsifyoufindanyconditionsoutlinedinSteps1,2and3.

5. Inspectthebearingouterracesforindentationscausedbyeitherdirtorforeignparticleshavinggonethroughthebearing.Youcancontinuetousethebearingiftheindentationsaresmallandtherearenotmanyofthem,otherwisereplacethebearings.

6. Inspecttherollersandconeforspalledareas.Bearingswithlargeindentationsorwithmanyindentationscanmeanthattherollersandconearestartingtospallout.Replacethebearingsifyoufindspalledareas.

7. Dipgoodbearingpartsinalightmineraloil(SAE-10)heatedto90°C(194°F)toavoidcorrosionbeforeyoureassemblethem.Ifthebearingisnotmountedimmediatelywrapinanoil-proofpaper.

Reassembling the BearingsReassembling the Armature Bearings

Duringreassembly,heatshrink-fittedpartsinanoventoapproximately100°C(212°F)andassemblethemhot.Ensurethatshrink-fittedpartsaretightagainstadjacentpartsaftertheyhavecooled.

Reassembling the Drive-End Bearing

Usethisproceduretoreassemblethedrive-endbearing:

1. Ifyouremovedtheinnersleeve,heatitto110°C(230°F)andshrinkitontotheshafttightagainsttheshoulder.

2. Spread0.5oz.ofgreaseontothesealsonthefollowingareas:

• Theinnerbearingcap

• Theouterbearingcap

• Theinnersleeve

3. Pack8.0oz.ofgreaseintotheoutercircumferenceoftheinnerbearingcap.

4. Installtheinnerbearingcaponthesleeve.

5. Heatandinstalltheflingertightagainstthesleeve.

6. Cleanandinspectthebearinginnerraceandtheshaftbearingfit;removeanynicksandburrs.

7. Heatandinstalltheinnerraceoftherollerbearingtightagainsttheflinger.

8. Installtheouterraceofthebearingintheframehead.

9. Filltherollerbearingcompletelywith29.0oz.ofgrease.

10. Installthegasketontotheinnerbearingcap.

11. Installtheguidepinsintotheinnerbearingcap toguidetheframeheadintoposition.

The

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47

The B

earings

12. Hoisttheframehead/bearingassembly.Slide itontotheshaft,overtheguidepinsuntilitis seatedagainstthebearingcapthenremove theguidepins.

13. Pack4.8oz.ofgreaseintotheoutercircumfer- enceoftheouterbearingcapandinstallthe bearingcapwithgaskettotheframehead.

14. Securetheassemblywithboltsand lockwashers.Torqueto105to115lbs-ft.For instructionsontheproperlubricationfor assembledhardware,seeLubricating Bolts.

Reassembling the Commutator-End Bearing (Shunt Wound Machines)

Usethisproceduretoreassemblethecommutator-endbearingsonshuntwoundmachines:

1. Pack2.2oz.ofgreaseintotheoutercircumferenceofinnerbearingcap.

2. Cleanandinspectthebearinginnerraceandtheshaftbearingfit;removeanynicksandburrs.

3. Heatandinstalltheinnerraceontotheshaft,tightagainsttheshoulder.

4. Spread0.25oz.ofgreaseontherunningsurfaceofthebearingrace.

5. Fillallvoidsintherollerbearingcompletelyfillingthemwithapproximately5.0oz.grease.

6. Temporarily,assembletheouterbearingcap,bearingouterraceandrollers,bearingcapandtwonewgasketstotheframeheadwithtwoboltsandwashers.

7. Tightentheboltssecurely.Youwillcompletethebearingassemblywhenyouassemblethearmatureintotheframe.Formoreinformation,seeAssembling the Armature in the Frame.

Reassembling the Commutator-End Bearing (Series Wound Machines)

Usethisproceduretoreassemblethecommutator-endbearingsonserieswoundmachines:

1. Cleanandinspectthebearingandtheshaftbearingfit;removenicksandburrs.

2. Ifyouremovedthesleeve,heatitto110°C(230°F)andshrinkitontotheshafttightagainsttheshoulder.

3. Pack5.25oz.greaseintotheoutercircumfer-enceofthecavityofbearinghousing.

4. Heatthebearinghousinginanovento100°C(212°F).

5. Whilethebearinghousingishot,assembletheballbearingintothehousingfirmlyagainsttheshoulderatthebottomofthebearingfit.

6. Fillallvoidsintheballbearingcompletelyfillingthemwithapproximately20.8oz.ofgrease.

7. Spread0.5oz.ofgreaseonthebearinghousingandbearingcapseals.

8. Heatthebearingandhousingassemblyinanovento100°C(212°F).

CAUTION: Do not heat the bearing and housing as-sembly above 100°C (212°F); higher temperatures may cause the oil to bleed from the grease.

9. Whilethebearingandhousingassemblearehot,assembleitontotheshaft,withtheinnerracetightagainstthesleeve.

10. Heatthespacerto110°C(230°F)andshrink itontotheshafttightagainsttheinnerraceof ballbearing.Youwillcompletethebearing assemblywhenyouassemblethearmature intotheframe.Formoreinformation,see Assembling the Armature in the Frame.

48

The HubsHub Fitting Topreventahubfromslipping,itshouldhaveatleast75percentfitontheshaft;thatisatleast85-90%ofthetaperedboreofthehubshouldbeincontactwiththetaperedfitontheshaft.Usethefollowingproce-duretocheckandcorrectthefitbeforemountingahub:

1. LightlycovertheboreofthehubwithablueingcompoundsuchasPrussianBlue.

2. Snapthecoldhubforcefullyontotheshaft.

3. Marktherelativeangularpositionofhubwithrespecttotheshaft.

4. Removethehubfromtheshaft.Youcanremovethehubbycarefullydrivingtwohardenandgroundfinelytaperedsteelwedgesbetweenthehubandthebearingoutersleeveontheshaft.

5. Inspectthetaperfitoftheshaft.Youshouldseetheblueingofthehubboreontheshaft. Thefitisimportant:

• Ifyouseetracesofblueingonatleast85-90%oftheshaftsurface,thefitissatisfactory.

• Ifyouonlyseeafewspotsofblueingontheshaft,thefitisnotsatisfactoryandyoumuststartagainatStep1.

6. DressdownthebluespotsontheshaftverylightlywithafineemeryclothsuchasNo.400ATriemite.

7. Bluethehubboreagain;repeatthisprocedureatStep1.

8. Placethehubontotheshaftinthesamepositionasmarked.Generally,thefitwillbeimproved,butyoumighthavetorepeatthisprocedureseveraltimestoobtaina85-90%fit.

CAUTION: Do not use a lapping compound. Lap-ping will produce a shoulder at the large end of the tapered fit that prevents a perfect fit when you mount the hub; that is when it is mounted in the advanced position.

9. Afteryouobtainatleasta85-90%fit,thoroughlycleantheshaftandthehubboretoremoveallblueing,oilorgrease.Formoreinformation,seeCleaning.

10. Mountthehub.

Mounting the HubYoumountthehubonceyouhavecompletedfittingthehub.Youmustalsobesurethattheshaftandhubborearecleanandfreeofanyscoring.

Usethefollowingproceduretomountthehub:

1. Spotthecoldhubontheshaftbyhandandcheckforafitofleast85-90%.Formoreinfor-mation,seeFitting the Hub.Ifnecessary,dresstheshafttoobtainafitofatleast85-90%.

2. Trialmountthecoldhubontotheshaft.

3. Usingamicrometeradvancegauge,measureandrecordthepositionofthehubwithrespecttotheendoftheshaft.

• Zerothegauge.

• Markpointsofmeasurement.

• Markacrosstheendoftheshaftandhubfacesothatwhenyouheatthehubyoucanmountitinexactlythesameangularposi-tion,andsoyoucanmaketheadvancemeasurementfromthesamepoint.

CAUTION: Make sure you do not change the zero settings of advance gauge until you have complet-ed all hub readings.

4. Measuretheshafttemperature.Whenmeasur-ingtheshafttemperatureandpointsinsidetheboreofthehub,useahandpyrometer(orotherinstrumentwhereyoucanquicklyandaccuratelymeasurethehubandshafttemperaturesbeforemountingthehub).Toensureyouhaveaccuratereadings,measurethetemperatureoftheshaftandthehubwiththesameinstrument.

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The H

ubs

5. Heatthehubinanovenuntilithasreachedauniformtemperatureabovetheshafttemperature(seedetailsbelow).Forexample,iftheshafttemperatureis25°C(77°F),heatthehubto25°C(77°F)+215°C(419°F)=240°C(464°F).

Note: You must leave the part in the oven long enough for the heat to penetrate throughout the part. Be sure the tem-perature of the hub does not exceed 250°C (482°F); other-wise, the hub may become annealed.

6. Withthehubstillhot,mountitontotheshaftsothattheadvancefromthecoldpositiontothehotpositionalongtheaxisoftheshaftisaslistedinthefollowingtable:

Hub Part Number

Advance (in.) Degrees RiseAbove Shaft Temp.

97A145 0.120-0.130 215°C (419°F)

Theseareestimateddifferencesbetweentheshafttemperatureandhubtemperature(temper-aturerise)toprovidethelistedadvance.Thetemperaturesatyourfacilitymightbedifferentandyoushouldadjustthetemperatures,ifrequired,toprovidetheadvancewithinpre-scribedlimits.

7. Ensurethatthehubboreandtheshafttaperareclean.

8. Usingproperhandprotection,quicklymountthehothubontotheshaftinthesameangularpositionaswhencold(Step2).

9. Whenthehubisnearlymountedwiththetaperfit–butnotactuallyincontact–forciblysnapitintoplacewithaquickpush.

CAUTION: It is important that you instantly snap the hot hub into position before it has a chance to cool, otherwise it will freeze to the shaft and you will not be able to change the position.

10. Checkthehotorshrunk-onpositionofthehub ontheshaft.Theadvancefromthecold positiontothehotpositionalongtheaxisofthe shaftmustbewithinthelimitsshowninthe tableabove.Checktheactualadvancewithan indicatorgauge.Makesureitislocatedinthe samerelativepositionaswhenyoumeasured thecoldpositioninStep4.Iftheadvanceis notwithinspecifiedlimits,removethehuband repeattheassemblyprocedure.

50

The

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The BoltsLubricating the BoltsTorquevaluesarebasedusinglubricatedbolts.Useasuitablehighpressurelubricant,suchasautomotivemotoroil.Lubricateboththethreadsandwasherfaceofthebolttoobtainmaximumclampingforce.

Note: You must clean threads and washer-contact surfaces before you apply a lubricant.

Thebasicclassificationsofboltedjointsareasfollows:

• Critical–lubricationisrequired.Inthiscase,theprocedurewillincludethetighteningtorquevalues. Lubricatetheboltsasspecifiedabove,then,usingatorquewrench,tightentheboltstothespecified torquevalue.

• Non-critical–lubricationisnotrequired,butrecommended.Inthiscase,notorquevaluesarespecifiedintheprocedure.Forthepropertorquevalues,seeStandard Bolt Torque Values.

51

Standard Bolt Torque ValuesThetorquevaluesinthistableprovideaguidefortighteninglubricatednutsandboltswhenspecificvaluesarenotlistedintheinstructions.

Bolt Diameter

Threads per inch

Torque ValuesMedium Carbon

(SAE GRADE 5) Alloy Steel(SAE GRADE 8)

Including Socket Head Screws

1/4 20 5-8 10-12 28 5-8 10-12

5/16 18 12-15 18-21 24 12-15 20-23

3/8 16 20-25 30-36 24 25-28 34-40

7/16 14 35-40 50-56 20 40-45 60-65

1/2 13 55-60 80-90 20 60-70 95-105

9/16 12 75-80 110-123 18 90-100 130-145

5/8 11 105-115 152-169 18 125-140 185-205

3/4 10 185-205 285-315 16 220-245 340-370

7/8 9 300-330 440-490 14 340-380 510-565

1 8 440-490 685-735 12 530-570 790-8665

1-1/8 7 620-690 935-1040 12 750-830 1115-1240

1-1/4 7 890-990 1250-1360 12 1040-1160 1600-1750

1-3/8 6 1160-1290 1745-1940 12 1420-1580 2125-2360

1-1/2 6 1570-1740 2300-2600 12 1800-2000 2600-3020

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IndexArmature Armature Varnish Treatment 32 Assembling the Armature into the Frame (Models YZE, YZK, ZE-F, ZK-F, ZE, ZK) 28 Assembling the Armature into the Frame (Models YZB, YZH, ZB-F, ZH-F, ZB, ZH) 30 Balancing the Armature 32 Inspecting and Testing the Armature 28 Locking the Armature for Shipment 31 Removing the Armature Locking Arrangement 31 Replacing the Armature Creepage Band 28 Testing the Armature After Repair 31

ATEX Certification Safety Considerations 13

Balancing the Armature 32

Bearings Inspecting the Bearings 46 Reassembling the Bearings 46

Bearing Reassembly Armature Bearings 46 Commutator-End Bearing (Series Wound Machines) 47 Commutator-End Bearing (Shunt Wound Machines) 47 Drive-End Bearing 46

Bolts Lubricating the Bolts 50 Standard Bolt Torque Values 51 Brazing the Coil Terminals Flood Dipping the Coiled Frame 37 Using the Gas Torch Brazing Method 36 Using the Machine Brazing Method 36

Brush and Brushholder Adjusting the Brushholder Clearance 27 Inspecting and Testing the Brusholders 27 Installing the Brushes 26 Installing the Brushholders 27 Reassembling Brushholders 28 Removing the Brushes 26 Replacing the Brushes 26 Replacing the Brushholders 26 Replacing the Brushholder Sleeves 27

Cleaning Cleaning Anti-Friction Bearings/ Shaft Tapers/Bearing Fits 25 Steam Cleaning 25 Vapor Degreasing 25

Closed Cooling Systems 15

Commutator Air Curing 45 Fixture Grinding 43 Grinding 43 Hand Stoning 42 Inspections 32 Preparing the Commutator for Resurfacing 41 Reassembly of Commutator-End Bearing (Series Wound Machines) 47 Reassembly of Commutator-End Bearing (Shunt Wound Machines) 47 Resurface Based on Condition 41 Sanding 42 Safety Requirements 41 Series Motors Resurface Preparation 41 Shunt Motors Resurface Preparation 42

Commutator Resurface Preparation Series Motors 41 Shunt Motors 42

Connection Boxes Assembling the Connection Box 39 Changing the Position of the Connection Box 38 Differences for Shunt Motors 40 Insulating the Terminal Connections 39

Differences between motor models 9

Electrical Parameters Grounding 15 Series Wound 14 Shunt Wound 14

Features, General 13 Flood Dipping the Coiled Frame 37

Frame Field Coil Flood Dipping 37 Installing the Coil 36 Removing the Coil 35

General Features 13

53

General Operating Information ATEX Certification Safety Considerations 13 Closed Cooling Systems 15 General Features 13 Grounding 15 Lubrication 15 Safe Electrical Parameters – Series Wound 14 Safe Electrical Parameters – Shunt Wound 14 Special Handling Requirements 15 Special Tools 16 Warnings 14

General Product Information 5 General Specifications 10 Grinding the Commutator 33

Grounding 15 Hubs Hub Fitting 48 Mounting the Hub 48

Inspection Prior to Operation 20 Inspections Inspecting the Armature Shaft Bearing Fits 32 Inspecting the Bearings 46 Inspecting the Commutator 32 Inspecting the Creepage Band 32 Inspecting the Insulation 32 Inspection prior to Operation 20 Inspections for Closed Cooling Systems 20 Semi-Annual Inspections 20 Monthly Inspections 17

Inspections for Closed Cooling Systems 20

Locking Locking the Armature for Shipment 31 Removing the Armature Locking Arrangement 31

Lubrication Bolts 50 General Lubrication 16

Monthly Inspections 17 Motor Disassembly Removing the Armature from the Frame 22 Removing the Hub 21

Motor Frame Brazing the Coil Terminals 36 Inspecting and Testing the Motor Frame 35 Replacing the Motor Frame Field Coil 35 Testing the Coiled Frame 37 The Connection Boxes 38

Motor Models 8 Motor Overhaul Disassembling the Motor 21 Testing the Motor before Disassembly 21

Parts List/Diagram 6 Polishing the Commutator 34 Raking the Commutator 34

Reassembling the Armature Bearings 46 Reassembling the Commutator-End Bearing (Series Wound Machines) 47 Reassembling the Commutator-End Bearing (Shunt Wound Machines) 47 Reassembling the Drive-End Bearing 46 Reassembly Armature Bearings 46 Commutator-End Bearing (Series Wound Machines) 47 Commutator-End Bearing (Shunt Wound Machines) 47 Drive-End Bearing 46

Resurface Preparation Air Curing the Commutator 45 Fixture Grinding 43 Grinding the Commutator 43 Hand Stoning the Commutator 42 Installing the Grinder 43 Preparing for Resurfacing for Series Motors 41 Preparing for Resurfacing for Shunt Motors 42 Sanding the Commutator 42

Resurfacing the Commutator Grinding 33 Polishing 34 Raking 34 Turning 33 Undercutting 33

Index

54

Series Wound Machines Electrical Parameters 14 Reassembling Commutator-End Bearing 47 Resurface Preparation 41 Safe Electrical Parameters 14 Testing After Overhaul 23

Shunt Wound Machines Electrical Parameters 14 Reassembling Commutator-End Bearing 47 Resurface Preparation 42 Safe Electrical Parameters 14 Testing After Overhaul 24

Safety ATEX Certification Safety Considerations 13 Electrical Parameters – Series Wound 14 Electrical Parameters – Shunt Wound 14

Semi-Annual Inspections 20

Special Handling Requirements 15 Special Tools 16

Specifications, General 10

Testing After Overhaul 23 Coiled Frame 37 Motor before Disassembly 21 Series Models 23 Shunt Models 24

Torque values, bolts 51 Turning the Commutator 33

Undercutting the Commutator 33 Warnings 14

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Joliet Equipment Corporation1DorisAve.Joliet,IL60433TollFree:800.435.9350Phone:815.727.6606WebAddress:www.joliet-equipment.com

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